GENERAL

01 GENERAL

General assembly drawing ........................... 01- 2

Specifications ................................................ 01-12
Weight table ................................................... 01-32
List of lubricant and water ............................ 01-42

PC27 – 45MRX-1 01-1

GENERAL GENERAL ASSEMBLY DRAWING

PC27MRX-1
• CAB SPECIFICATION

ª1: This shows the minimum swing radius for the work equipment.
ª2: This shows the dimensions at boom swing.

PC27 – 45MRX-1 01-3

GENERAL GENERAL ASSEMBLY DRAWING

PC30MRX-1

ª1: This shows the minimum swing radius for the work equipment.
ª2: This shows the dimensions at boom swing.

01-4 PC27 – 45MRX-1

GENERAL GENERAL ASSEMBLY DRAWING

PC30MRX-1
• CAB SPECIFICATION

ª1: This shows the minimum swing radius for the work equipment.
ª2: This shows the dimensions at boom swing.

PC27 – 45MRX-1 01-5

GENERAL GENERAL ASSEMBLY DRAWING

PC35MRX-1
• CAB SPECIFICATION (Rubber shoe/steel shoe spec.)

ª1: This shows the minimum swing radius for the work equipment.
ª2: This shows the dimensions at boom swing.

PC27 – 45MRX-1 01-7

GENERAL SPECIFICATIONS

PC30MRX-1
Machine model
Canopy specification Cab specification

Serial number 10001 and up

Bucket capacity m3 0.09 0.09

Operating weight kg 3,200 (ª3,300) 3,310 (ª3,420)

Max. digging depth mm 2,835 2,835

Max. vertical wall depth mm 2,535 2,535
Working ranges

Max. digging reach mm 5,145 5,145

Max. reach at groung level mm 5,030 5,030
Max. digging height mm 4,600 4,600
Max. dump ing height mm 3,135 3,135
Bucket offset mm 510 (L.H.), 710 (R.H.) 510 (L.H.), 710 (R.H.)
Max. blade lifting height mm 330 330
Max. blade lowering depth mm 245 245

Max. digging force (bucket) kN {kg} 27.4 {2,800} 27.4 {2,800}

Performance

Swing speed rpm 9.3 9.3

Swing max. slope angle ° 19 19
Travel speed km/h 4.6 (Hi) / 2.8 (Lo) 4.6 (Hi) / 2.8 (Lo)
Gradeability ° 30 30
Ground pressure (at rubber shoe) kPa {kg/cm2} 29.3 {0.30} 30.3 {0.31}
Ground pressure (at steel shoe) kPa {kg/cm2} 30.2 {0.31} 31.3 {0.32}
Swing machinery Swing circle

Reduction ratio 89/11= 8.09

Grease G2-LI (Albania EP-2)

Reduction ratio 17.42

Swing reduction ratio 140.94
Swing speed rpm 9.3
Lubrication oil EO10-CD
Lubrication oil amount ¬ 0.9

Ovarall length (for transport) mm 4,660 4,660

Overall width mm 1,550 1,550
Dimensions

Overall width (crawler) mm 1,550 1,550

Overall height (for transport) mm 2,460 (ª2,455) 2,510 (ª2,505)
Ground clearance of conterweight mm 560 560
Min. ground clearance mm 320 320
Tail swing radius mm 855 855

ª For steel shoe specification.

01-16 PC27 – 45MRX-1

GENERAL SPECIFICATIONS

PC30MRX-1
Machine model
Canopy specification Cab specification

Serial number 10001 and up

Min. swing radius of work equip- 2,135 (1,810) 2,135 (1,810)

ment (at boom swing) mm

Min. swing radius of work equip- 3,560 3,560

ment mm
Dimensions

Length of track on ground mm 1,610 (ª1,608) 1,610 (ª1,608)

Track gauge mm 1,250 1,250
Machine cab height mm 1,440 1,440
Blade width mm 1,550 1,550
Blade height mm 325 325

Model 3D84E-3K
Type 4-cycle, water cooled, in-line direct injection type
No. of cylinders – bore × stroke mm 3 – 4 × 90
Piston displacement ¬ {cc} 1.490 {1,496}

Fly wheel horsepower kW/rpm {HP/rpm} 20.6/2,500 {27.6/ 2,500}

Performance

Maxium torque Nm/rpm {kgm/rpm} 85.3/1,800 {8.7/1,800}

High idling speed rpm 2,700
Low idling speed rpm 1,150
Min. fuel consumption ratio g/kWh {g/HPh} 231 {172}
Engine

Starting motor 12V, 1.2 kW

Alternator 12V, 40A
Battery 12V, 68Ah × 1 (FZG-D26L))

Radiator
• Core type CF24-1
• Fin pitch mm 3.0/ 2
• Heat dissipation area m2 5.24
• Pressure valve cracking pressure kPa {kg/cm }2
88.3 ± 14.7 {0.9 ± 0.15}
2
• Vacuum valve cracking pressure kPa {kg/cm } 4.9 {0.05}

Carrier roller 1 on each side

Track roller 4 on cach side
Under-carriage

Track shoe (Rubber shoe) Rubber pad shoe

Track shoe (Steel shoe) Double grouser: 43 each side

Recoil spring
• Grease KOMATSU genuine Hyper White grease
• Amount of grease cc —

PC27 – 45MRX-1 01-17

GENERAL SPECIFICATIONS

PC30MRX-1
Machine model
Canopy specification Cab specification

Serial number 10001 and up

Cylinder type Double acting piston Double acting piston

Boom sylinder

Inside diameter of cylinderylinder mm 75 75

Outside diameter of piston rod mm 45 45
Stroke mm 499 499
Max. distance between pins mm 1,365 1,365
Min. distance between pins mm 866 866

Cylinder type Double acting piston Double acting piston

Arm sylinder

Inside diameter of cylinderylinder mm 75 75

Outside diameter of piston rod mm 40 40
Stroke mm 495 495
Max. distance between pins mm 1,275 1,275
Min. distance between pins mm 780 780

Cylinder type Double acting piston Double acting piston

Hydraulic system

Working sylinder
Bucket sylinder

Inside diameter of cylinderylinder mm 65 65

Outside diameter of piston rod mm 40 40
Stroke mm 490 490
Max. distance between pins mm 1,270 1,270
Min. distance between pins mm 780 780

Cylinder type Double acting piston Double acting piston

Brade sylinder

Inside diameter of cylinderylinder mm 80 80

Outside diameter of piston rod mm 40 40
Stroke mm 135 135
Max. distance between pins mm 561 561
Min. distance between pins mm 426 426
Boom swing sylinder

Cylinder type Double acting piston Double acting piston

Inside diameter of cylinderylinder mm 80 80
Outside diameter of piston rod mm 40 40
Stroke mm 422 422
Max. distance between pins mm 1,195 1,195
Min. distance between pins mm 773 773

PC27 – 45MRX-1 01-19

GENERAL WEIGHT TABLE

Unit: kg

PC30MRX-1
Machine model
Canopy specification Cab specification

Serial number 10001 and up

Engine assembly (with out oil, water) 209.6 209.6

• Engine 163 163
• Engine mount 18.6 18.6
• P.T.O 5.5 5.5
• Hydraulic pump 22.5 22.5

Radiator assembly 18 18

Revolving frame 348 363

Operator's cab — 206

Canopy assembly 72.1 —

Operator's seat 10.7 10.7

Fuel tank (without fuel) 6 6

Hydraulic tank (without hydraulic oil) 32 32

Control valve 33.2 33.2

Counterweight (with weight) 634 445

Swing motor (with brake valve) 13.7 13.7

Swing machinery 22.8 22.8

Center swivel joint 14.8 14.8

01-34 PC27 – 45MRX-1

GENERAL WEIGHT TABLE

Unit: kg

PC30MRX-1
Machine model
Canopy specification Cab specification

Serial number 10001 and up

Track frame assembly 754 754

• Track frame 345 345
• Carrier roller 3.3 × 2 3.3 × 2
• Track roller 6.6 × 8 6.6 × 8
• Recoil spring assembly 18 × 2 18 × 2
• Idler 20.9 × 2 20.9 × 2
• Travel motor (with reduction gear) 37 × 2 37 × 2
• Sprocket 7.1 × 2 7.1 × 2
• Swing circle assembly 35.6 35.6

Track shoe assembly

• Rubber shoe (300 mm) 123 × 2 123 × 2
• Double grouser shoe (300 mm) 168 × 2 168 × 2
• Road liner (300 mm) 188 × 2 188 × 2

Boom swing bracket assembly 53 53

Boom assembly 98.7 98.7

Arm assembly 49.3 49.3

Bucket assembly (with side cutter: width 500 mm) 66 66

Blade assembly 143 143

Boom cylinder assembly 23.5 23.5

Arm cylinder assembly 19.6 19.6

Bucket cylinder assembly 17.7 17.7

Boom swing cylinder assembly 20.1 20.1

Blade cylinder assembly 14 14

PC27 – 45MRX-1 01-35

GENERAL LIST OF LUBRICANT AND WATER

NOTE:
• When fuel sulphur content is less than 0.5 %,
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table if
fuel sulphur content is above 0.5 %.

Change interval of
Fuel sulphur content oil in engine oil pan
0.5 to 1.0 % 1/2 of regular interval
Above 1.0 % 1/4 of regular interval

• When starting the engine in an atmospheric

temperature of lower than 0°C, be sure to use
engine oil of SAE10W, SAE10W-30 and
SAE15W-40, even though an atmospheric tem-
perature goes up to 10°C more or less in the
day time.
• Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
• There is no problem if single grade oil is mixed
with multigrade oil (SAE10W-30, 15W-40), but
be sure to add single grade oil that matches
the temperature in the table on the left.
• We recommend Komatsu genuine oil which
has been specifically formulated and approved
for use in engine and hydraulic work equip-
ment applications.

ª1: For the HO46-HM, use the oil recommended

by Komatsu.

ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including
oil for components and oil in
piping.
Refill capacity: Amount of oil needed to refill
system during normal inspec-
tion and maintenance.

PC27 – 45MRX-1 01-43

STRUCTURE AND FUNCTION ENGINE CONTROL

ENGINE CONTROL
This diagram shows PC30MRX.

SWP05245

1o-2 PC27 - 45MRX-1

0
STRUCTURE AND FUNCTION ENGINE CONTROL

1. Battery
2. Fuel control lever
3. Starting switch
4. Fuel feed pump
5. Starting motor
6. Cable
7. Engine stop solenoid
8. Fuel injection pump

Lever position
(1) Low idling
(2) Full

Function
. Engine can be started and stopped simply by
the starting switch (3).
. Engine stop solenoid has a fail-safe mecha-
nism which acts to drive the fuel injection
pump stop lever to the RUN position when
the starting switch is turned ON, so if there is
any abnormality in the electrical system, the
engine stops.
. Fuel control lever(2) is used to control the
engine speed.

PC27 - 45MRX- 1 1o-3

0
STRUCTURE AND FUNCTION PTO

PTO
PC27MRX, PC30MRX-1
This diagram shows PC27MRX.

---- /

I
>’
/”

A-A SWPO6135

1. Case
2. Shaft

1o-4 PC27 - 45MRX- 1

a
STRUCTURE AND FUNCTION PTO

PC35MRX, PC40MRX, PC45MRX-1

This diagram shows PC40MRX.

9JA00690

1. Boss
2. Spring pin
3. Rubber
4. Cover
5. Hydraulic pump

PC27 - 45MRX- 1 1o-5

a
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER

RADIATOR AND OIL COOLER

PC27MRX, PC30MRX-1

I
IO
SWPO5244

1. Radiator outlet hose 6. Radiator cap

2. Fan guard 7. Radiator
3. Radiator inlet hose 8. Fan
4. Shroud 9. Reserve tank
5. Oil cooler 10. Drain valve

1O-6 PC27 - 45MRX-1

0
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER

PC35MRX-1

9JA00691

1. Shroud 7. Fan guard

2. Reservoir tank 8. Radiator outlet hose
3. Oil cooler 9. Drain valve
4. Radiator cap 10. Oil cooler inlet
5. Radiator 11. Oil cooler outlet
6. Radiator inlet hose

PC27 - 45MRX- 1 1o-7

0
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER

PC40MRX, PC45MRX-1

5 El

_______---- \ -____ I

II 9JAO0692

7. Reservoir tank
1. Radiator cap 8. Radiator outlet hose
2. Oil cooler 9. Drain valve
3. Radiator IO. Oil cooler inlet
4. Shroud 11. Oil cooler outlet
5. Radiator inlet hose
6. Fan guard

PC27 - 45MRX- 1
1O-8
0
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER

SPECIFICATIONS
Radiator

Model 1 PC27MRX 1 PC30MRX 1 PC35MRX 1 PC40MRX 1 PC45MRX

Core type I CF24-1 1 CF23-2 1 CF27-2

Fan pitch b-nm) I 3.012 I 4.012

Total heat dissipation surface (m*) 5.24 6.2 9.3

Pressure valve cracking pressure
88.3+14.7{0.9*0.15}
(kPaIkg/cm*I)

Vacuum valve cracking pressure

4.9{0.051
(kPa~kg/cm*I)

Oil cooler

Model PC27MRX PC30MRX PC35MRX PC40MRX PC45MRX

Core type DRAWN-CUP AL-CFT AL-CFT-1

Fan pitch (mm) I 4.012 I 4.512

Total heat dissipation surface (m2) I 2.06 I 2.62 I 3.31

PC27 - 45MRX- 1 1o-9

a
 POWER TRAIN
STRUCTURE AND FUNCTION .

PC27MRX, 30MRX-1
This diagram shows PC30MRX.

10

SWPO5246

10-10 PC27 - ISMRX- 1

a
STRUCTURE AND FUNCTION POWER TRAIN

1. Idler
2. Control valve
3. Center swivel joint
4. Swing motor
5. Travel motor
6. Engine
7. Hydraulic pump
8. Hydraulic pump (For swing and blade)
9. Traveling Hi-Lo speed selector valve
10. Swing circle

A. Swing
6. Control valve

PC27 - 45MRX- 1 10-11

a
STRUCTURE AND FUNCTION POWER TRAIN

PC35MRX, 45MRX-1
This diagram shows PC40MRX.

\
II 9JA00693

7. Travel Hi-Lo speed selector valve

1. Swing motor 8. Center swivel joint
2. Control valve 9. Idler
3. R.H. travel motor 10. Swing machinery
4. Engine 11. Swing circle
5. Hydraulic pump
6. L.H. travel motor

10-12 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION SWING CIRCLE

SWING CIRCLE
This diagram shows PC40MRX,45MRX.

A-A 9JA00694

1. Swing circle bearing lubricator 4. Inner race

2. Swing circle pinion lubricator 5. Seal
3. Ball 6. Outer race

a. Inner race soft zone position

b. Outer race soft zone position

Specifications
Model PC27MRX 1 PC30MRX PC35MRX PC40MRX 1 PC45MRX

Reduction ratio 98/l 1=8.09 95/l 1=8.36 78/I 0=7.8

Grease G2-LItAlbania EP - 2)

PC27 - 45MRX-1 10-13

0
STRUCTURE AND FUNCTION SWING MACHINERY

SWING MACHINERY
This diagram shows PC30MRX.

B-B
--_ -“\ A
-_ 1 \

SWPO5248

1. Swing motor 6. No. 2 planetary gear

2. No.1 sun gear 7. Swing machinery case
3. No.1 planetan/ gear 8. Swing pinion
4. No.2 sun gear 9. Taper roller bearing
5. Ring gear

10-14 PC27 - 45MRX-1

0
STRUCTURE AND FUNCTION SWING MACHINERY

SPECIFICATIONS

Model PC27MRX PC30MRX PC35MRX PC40MRX PC45MRX

Reduction ratio 17.42 26.45

Swing reduction ratio 140.94 145.63 206.30

Swing speed (rpm) 9.3 8.5 9.0

Lubrication oil I EDIO-CD

Oil amount (!I I 0.9 I 1.3

PC27 - 45MRX- 1 10-15

0
STRUCTURE AND FUNCTION TRACK FRAME

TRACK FRAME
PC27MRX, PC30MRX-1
This diagram shows PCSOMRX.

‘6 9JAD0695

1. Idler 5. Sprocket
2. Track frame 6. Track roller
3. Carrier roller 7. Idler cushion
4. Travel motor 8. Track shoe

10-16 PC27 - 45MRX-1

0
STRUCTURE AND FUNCTION TRACK FRAME

PC35MRX, PC40MRX, PC45MRX-1

This diagram shows PC40MRX.

9JA00696

1. Idler 6. Track roller

2. Track frame 7. Idler cushion
3. Carrier roller 8. Track shoe
4. Travel motor 9. Idler guard (only steel shoe spec.)
5. Sprocket

PC27 - 45MRX- 1 10-17

0
STRUCTURE AND FUNCTION IDLER CUSHION

IDLER CUSHION
PC27MRX, 30MRX-1
This diagram shows PC30MRX.

i 3 i
A-A SWPO5250

1. Idler 5. Spring
2. support 6. Nut
3. Cylinder 7. Lubricator
4. Rod

lo-18 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION IDLER CUSHION

PC35MRX, PC40MRX, PC45MRX-1

This diagram shows PC40MRX and PC45MRX.

‘._ 1
\ ---..____._.__.__________
“-._ -----_._..-._-._______~ -:_-~.-.-_T~~.

A-A 9JA00697

1. Idler 6. Cylinder
2. support 7. Recoil spring
3. Plate 8. Rear support
4. Cover 9. Nut
5. Rod 10. Lubricator

Specifications
Model PC27MRX 1 PC30MRX 1 PC35MRX 1 PC40MRX 1 PC45MRX
Grease Komatsu hvper white bearing grease
Amount of grease kc) 1 120

PC27 - 45MRX- 1 10-19

0
 HYDRAULIC PIPING
STRUCTURE AND FUNCTION

HYDRAULIC PIPING
PC27MRX, PCSOMRX, PC35MRX-1

1. Bucket cylinder
2. Arm cylinder
3. Boom swing cylinder
4. Hydraulic tank
5. Hydraulic filter (installed in tank)
6. Oil cooler
7. R.H. work equipment PPC valve
8. L.H. work equipment PPC valve
9. L.H. travel motor
10. Hydraulic pump
11. Solenoid valve
12. Control valve
13. Center swivel joint
14. Swing motor
15. Blade cylinder
16. Boom cylinder

SWPO5251 +

PC27 - 45MRX- 1
1O-20
0
STRUCTURE AND FUNCTION HYDRAULIC PIPING

15 14

9JA00696

PC27 - 45MRX- 1 10-21

0
STRUCTURE AND FUNCTION VALVE CONTROL

VALVE CONTROL
PC27MRX, PC30MRX, PC35MRX-1

‘I2 9JA00701

1 O-24 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION HYDRAULIC TANK

HYDRAULIC TANK
PC27MRX, PCSOMRX-I

3
_-------m----
,/=
m

----p_------------
4 SWPO5254

1. Sight gauge 4. Drain plug

2. Filler plug 5. Filter element
3. Hydraulic tank 6. Strainer

PC27 - 45MRX- 1 1O-29

0
STRUCTURE AND FUNCTIObl HYDRAULIC TANK

PC~~MRX-1

3 B-B

I I

A-A

_ c4 _________~ 9JA00706

1. Sight gauge 5. Filler plug

2. Hydraulic tank 6. Drain plug
3. Bypass valve 7. Strainer
4. Filter element

1O-30 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION HYDRAULIC TANK

SPECIFICATIONS

Model 1 PC27MRX 1 PCSOMRX 1 PC35MRX 1 PC40MRX 1 PC45MRX

Tank capacity (e) I 47 I 45 I 48

Oil amount (1) 28.5 28.5 33

Bypass valve cracking pressure

103f19.6 {1.05+0.2}
(kPa{kg/cnYI)
Pressure valve cracking pressure - 38.2f14.7 {0.39*0.15}
Wa{kg/cm*I)

Vacuum valve cracking pressure - 0 to 4.9 IO to 0.051

WaIkg/cm*I)

lo-32 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION CLSS

CLSS
OUTLINE
Features Structure
The term “CLSS” stands for the “Closed center l The CLSS consists of a variable displacement
Load Sensing System” which has the following single piston pump, control valve and actua-
features. tors.
1) Fine-controllability not affected by loads. l The pump body consists of the main pump,
2) Controllability enabling digging even in the PC valve and LS valve.
fine control mode.
3) Complex operability ensured by flow distri-
bution determined according to the opening
area of spools during complex operation.
4) Energy-saving feature using variable pump
control.

( Actuators )

~--____-----------_+~

TCC valve -------1

I
II
I II
II
L__________________
is valve -------I
I

SKP04139

PC27 - 45MfU- 1 1o-33

0
STRUCTURE AND FUNCTION CLSS

BASIC PRINCIPLE
1. Control of pump swash plate angle
l The pump swash plate anglelpump discharge
amount) is controlled so that LS differential
pressure APLS ( the difference between pump
pressure PP and control valve outlet port LS
pressure PLSNoad pressure of actuator) is
constant.
(LS pressure APLS =Pump discharge pressure
PP - LS pressure PLS)
l If LS differential pressure APLS becomes
lower than the set pressure of the LS valve,
the pump awash plate move towards the
maximum position; if it becomes higher than
the set pressure of the LS valve, the pump
awash plate moves towards the minimum
position.
For detail of swash plate operation, refer the “Hy-
draulic pump”
Actuator

Control valve

i________
-------7

I 8 L
I I PLS 0 LS differential t
Pump Passase II Pressure ARs Set differential
jj Dressure of LS valve
1.-----------ILS Passase SKP04141
Main Dump
7I

r---B
PD

Min. Max.

I I
Servo
piston
I-l
I I
j j
APLS , ,
II II

SKP04140

PC27 - 45MRX- 1
STRUCTURE AND FUNCTION CLSS

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
AP 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 Sl and S2 of each valve.

Load Load

AP AP
l-

Pressure Pressure
compensation compensat ion
valve valve

SXP07222

PC27 - 45MRX-1 1o-35

0
STRUCTURE AND FUNCTION

OPERATION FOR EACH FUNCTION AND VALVE

Hydraulic circuit diagram and name of valve
PC27MRX. PC30MRX-1

TS
t
+ Swing

_--c--_

104
___I___ ._ib_.
&I4

Blade
r

PA

-is11
Swing
r

PA
--_ k
_-----_ Bucket
B

II II
8=
__L___ Arm

k
-__ ---
r 12
jE& ,A3
/PB3
Boom

is2
v L. H. travel

+3 R.H.travel

SXPO7223

1O-36 PC27 - 45MRX- 1

a
STRUCTURE AND FUNCTION CLSS

1. Unload valve
Set pressure :
LS pressure + 2.45 MPa (25.0 kg/cm*]
2. Safety valve
Set pressure : 27.9 MPa I285 kg/cm21
(PC30MRX)
Set pressure : 28.9 MPa (295 kg/cm21
(PC40MRX, PC45MRX)
3. Main relief valve
Set pressure : 26.0 MPa I265 kg/cm21
4. Junction valve
5. Logic valve
6. Throttle valve
7. LS pressure reducing valve
8. Pressure compensation valve
9. Suction valve
10. Pilot pressure check valve
11. Check valve
12. Lift check valve
Set pressure : 0.14 MPa II.40 kg/cm21
13. Cooler bypass valve
Set pressure : 0.40 MPa 14.0 kg/cm21
14. Blade RAISE relief valve
Set pressure : 15.7 MPa 1160 kg/cm’)
15. Swing relief valve
(for gear pump)
Set pressure : 21.6 MPa (220 kg/cm21

PC27 - 45MRX- 1 1o-39

0
STRUCTURE AND FUNCTION CLSS

I-
Z-

3-
4-
5-
6-

7=
8-
8-
IO”
IlZ

12z
13=

142

SVPO5325

PC27 - 45MRX- 1 10-75

0
STRUCTURE AND FUNCTION CLSS

1) Operation (When all control valves are at

HOLD)
l Pump discharge amount 01 all flows unload
valve (8) to tank (1).
l None of the spool (each spool A) is being op-
erated, LS pressure PLS is not generated.
At the same time, this LS pressure PLS is con-
nected to the seal drain circuit by LS bypass
plug (6), so it is the tank pressure.
l In this condition, LS differential pressure APLS
becomes the unload pressure -tank pressure,
of LS valve (4), so main pump (2) is set to the
minimum swash plate angle.
l Gear pump (5) discharge amount Q2 flows
swing spool (9A) to tank (1) (open center).

1. Hydraulic tank 14. Boom control valve

2. Main pump 14A. Boom spool
3. Servo piston 148. Pressure compensation valve
4. LS valve (flow control valve)
5. Gear pump (for swing and blade) 14C. Pressure compensation valve
6. LS bypass valve (pressure reducing valve)
7. Self pressure reducing valve 14D. Suction valve
8. Unload valve 15. L.H travel control valve
9. Swing control valve 15A. L.H travel spool
9A. Swing spool 15B. Pressure compensation valve
IO. Blade control valve (flow control valve)
IOA. Blade spool 15C. Pressure compensation valve
IOB. Breaker spool (pressure reducing valve)
IOC. Suction valve 16. R.H. travel control valve
11. Swing control valve 16A. R.H. travel spool
1 IA. Swing spool 16B. Pressure compensation valve
11 B. Pressure compensation valve (flow control valve)
(flow control valve) 16C. Pressure compensation valve
11 C. Pressure compensation valve (pressure reducing valve)
(pressure reducing valve) 17. Boom cylinder
12. Bucket control valve 18. Arm cylinder
12A. Bucket spool 19. Bucket cylinder
12B. Pressure compensation valve 20. Boom swing cylinder
(flow control valve) 21. Blade cylinder
12C. Pressure compensation valve 22. L.H. travel motor
(pressure reducing valve) 23. R.H. travel motor
12D. Suction valve 24. Swing motor
13. Arm control valve 25. Cooler bypass valve
13A. Arm spool
13B. Pressure compensation valve
(flow control valve)
13C. Pressure compensation valve
(pressure reducing valve)
13D. Suction valve

1O-76 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION CLSS

2) When swing operated singly.

Ii;
-

I
i
-

SVP05326

lo-78 PC27 - 45MRX- 1

a
STRUCTURE AND FUNCTION CLSS

3
4
5‘1

---
d

Iri SVPO5327

PC27 - 45MRX- 1 1o-79

0
STRUCTURE AND FUNCTION CLSS

r I

r
Ir
I-

11
2

il
r
---
I Y
1 l
SVPO5329

PC27 - 45MfW 1 IO-83

0
STRUCTURE AND FUNCTION CLSS

4) When left and right travel are operated at same time.

/ II II
-! l , J I I I
,, I

SVPO5330

lo-86 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION CLSS

r I

SVPO5331

PC27 - 45MRX- 1 1 O-87

0
STRUCTURE AND FUNCTION

5) Actuators are operated at same time (for example, boom and arm)

n
r= 11 M

SVPO5511

1O-90 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION CLSS

@=I3
_---
__J
u

14

SVPO5512

PC27 - 45MRX-1 10-91

0
STRUCTURE AND FUNCTION CLSS

Operation (Actuators are operated at same time)

If boom spool (14A) is operated to RAISE and
arm spool (13A) is operated at the same time
to OUT, pump (2) discharge amount Q flows
to each cylinder (17) and (18).
When this happens, the load pressure of
boom cylinder (17) is greater than the load
pressure of arm cylinder (18), so the oil tries
to flow to arm cylinder (181, where the load
pressure is low. However, the pressure on the
upstream side of arm spool (13A) is compen-
sated by pressure compensation valves (14B)
and (140, which receive the load pressure of
the boom (= maximum LS pressure PLS).
In this way, the pressure difference between
the upstream pressure and downstream pres-
sure of boom spool (14A) and arm spool (13A)
becomes equal, so the flow of oil from main
pump (2) is divided in proportion to the area
of opening of each spool.
If the area of opening of boom spool (14A)
and arm spool (13A) is lOO%, even if pump
discharge amount Q becomes lOO%, LS dif-
ferential pressure APLS is set so that it does
not reach the LS valve (4) set differential pres-
sure, so main pump (2) is held at the maxi-
mum swash plate angle.
If the area of opening of boom spool (14A)
and arm spool (13A) is less than lOO%, pump
discharge amount Q is controlled in accor-
dance with the area of opening of the spools
by LS differential pressure APLS.

1O-92 PC27 - 45MRX- 1

CD
STRUCTURE AND FUNCTION SOLENOID VALVE

SOLENOID VALVE
FOR TRAVEL SPEED SOLENOID AND PPC LOCK
PC27MRX, PC30MRX-1

SWPO5293

A : To PPC valve
B : To travel speed solenoid
P : To pump
T : From hydraulic tank

1. Valve body
2. Solenoid

lo-108 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION SOLENOID VALVE

PC35, PC40, PC45MRX-’

Y-Y 9JA00708

A : To PPC valve Solenoid valve Control relief valve

B : To travel speed solenoid 3. Solenoid 8. Lock nut
P : To pump 4. Push pin 9. Adjust screw
T : From hydraulic tank 5. Spool 10. Shim
G : Check port 6. Return spring 11. Spring
7. Valve body 12. Spool
1. PCC lock solenoid valve
2. Travel speed solenoid valve

PC27 - 45MRX-1 10-109

0
STRUCTURE AND FUNCTION SOLENOID VALVE

Operation
When solenoid is deactivated
l When the signal current does not flow from
PPC oil pressure lock switch, or travel Hi-Lo
speed selector switch solenoid (1) is deacti-
vated.
For this reason, spool (2) is pushed to the
upper direction by spring (3).
l As a result, port P closes and the pressurized
oil from the control pump does not flow to
the actuator.
l At the same time, the pressurized oil from the
actuator flows from port A to the tank.

valve

Main Pump

SXPO7246

When solenoid is excited

l When the signal current flows from the con-
troller to coil (3), coil (3) is excited, and a pro-
pulsion force is generated in plunger (2) to
the right in the direction of the arrow.
l For this reason, spool (2) is pushed to the
down direction by push pin (5).
l As a result, the pressurized oil from the con-
trol pump flows from port P to port A passing
inside of spool (21, and then flows to the ac-
tuator.
At the same time, port T is closed, and this
stops the oil from flowing to the tank.

SXPO7246

10-110 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION CONTROL VALVE

CONTROL VALVE
* The sketch shows the standard valve
* The control valve is an add-on type where one
service valve each can be added, so it is pos-
sible to add valves or remove valves if neces-
sary.
* The service valve is added on between the
8th valve (swing valve) and cover assembly.
* The cross section of the service valve is the
same as the bucket valve of the standard
valve.

PC27MRX, PC30MRX-1

C : To oil cooler
S : To swing motor S port
T :Totank
Al : To R.H. travel motor
A2 : To L.H. travel motor
A3 : To boom cylinder bottom
A4 : To arm cylinder bottom
A5 : To bucket cylinder bottom
A6 : To boom swing cylinder bottom
A7 : To blade cylinder bottom
A8 : To swing motor MA
A9 : To breaker
Bl : To R.H. travel motor
B2 : To L.H. travel motor
B3 : To boom cylinder head
B4 : To arm cylinder head
B5 : To bucket cylinder head
B6 : To boom swing cylinder head
B7 : To blade cylinder head
B8 : To swing motor MB
LS : To pump LS valve
PI : From main pump to variable pump
P2 : From main pump to gear pump
PA3 : From boom RAISE valve
PA4 : From arm IN PPC valve
PA5 : From bucket CURL PPC valve
PA8 : From swing R.H. PPC valve
PA9 : From breaker PPC valve
PB3 : From boom LOWER valve
PB4 : From arm OUT PPC valve
PB5 : From bucket DUMP PPC valve
PB8 : From swing L.H. PPC valve
PC : To PPC valve P
PP : To pump LS valve
PS : To swing motor B
TS : To tank

10-112 PC27 - 45MRX-1

0
STRUCTURE AND FUNCTION CONTROL VALVE

(l/5)

PB8

PS

PA9

PBS

PB4

PB3

I
PC c
/ B-J-J
C
\ \
LS T

TS

SWPO5298

PC27 - 45MRX-1
 c
STRUCTURE AND FUNCTION CONTROL VALVE

15

SWPO5300

1. Self pressure reducing se- 8. Swing relief valve (for gear 15. Pressure compensation valve
quential valve pump) (pressure reducing valve)
2. Pressure compensation valve 9. Spool (breaker) (L.H.. travel)
(float control valve) 10. Pressure compensation valve 16. Pressure compensation valve
(R.H.. travel) (piston) (swing/breaker) (pressure reducing valve)
3. Pressure compensation valve 11. Pressure compensation valve (R.H.. travel)
(float control valve) (pressure reducing valve) 17. LS bypass plug
(L.H.. travel) (swing/breaker) 18. Unload valve
Pressure compensation valve 12. Pressure compensation valve 19. Cooler bypass valve
(float control valve) (boom) (pressure reducing valve) 20. Lift check valve
Pressure compensation valve (bucket) 21. Cooler bypass valve
(float control valve) (arm) 13. Pressure compensation valve 22. Pressure compensation valve
Pressure compensation valve (pressure reducing valve) (float control valve)
(float control valve) (bucket) (arm) 23. Spool (travel)
Pressure compensation valve 14. Pressure compensation valve 24. Pressure compensation valve
(float control valve) (float con- (pressure reducing valve) (pressure reducing valve)
trol valve) (swing/breaker) (boom)

PC27 - 45MRX- 1 10-115

0
STRUCTURE AND FUNCTION CONTROL VALVE

(5/51

16
I

N-N

SWPO5302

1. Pressure compensation valve (float control 9. Swing relief valve (for gear pump)
valve) 10. Pilot pressure check valve
2. Spool 11. Spool (breaker)
3. Check valve 12. Suction valve
4. Suction valve 13. Check valve
5. Pressure compensation valve (pressure reduc- 14. Blade RAISE relief valve (with suction)
ing valve) 15. Spool (blade)
6. Piston 16. Air bleeding plug
7. Pilot pressure check valve
8. Spool

PC27 - 45MRX-1 10-117

0
STRUCTURE AND FUNCTION CONTROL VALVE

(l/6)
* Control valve for PC35MRX differ the travel
spool attaching direction only. This diagram
show in case of PC40MRX and PC45MRX.

PA8

PS

PA9

PA5

PA4

PA3

Bl Al

9JUOOO24

PC27 - 45MRX- 1 10-119

0
STRUCTURE AND FUNCTION CONTROL VALVE

W6)

A-A

9JUOOO26

1. Suction valve (travel) 14. Main relief valve

2. Suction valve (travel) 15. Suction valve (travel)
3. Suction valve (boom bottom) 16. Spool (R.H.. travel) (PC35MRX)
4. Suction valve (arm bottom) 16. Spool (L.H.. travel) (PC4OMRX, PC45MRX)
5. Suction valve (bucket bottom) 17. Spool (L.H.. travel) (PC35MRX)
6. Suction valve mount port blind plug 17. Spool (R.H.. travel) (PC40MRX, PC45MRX)
(swing bottom) 18. Spool (junction valve)
7. Suction valve (blade bottom) 19. Spool (boom)
8. Blade RAISE relief valve (with suction) 20. Spool (arm)
9. Suction valve (swing head) 21. Spool (bucket)
10. Suction valve (bucket head) 22. Spool (boom swing)
11. Suction valve (boom head) 23. Spool (blade)
12. Safety valve 24. Spool (swing)
13. Suction valve (travel)

10-120 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION CONTROL VALVE

B/6)

I 23

24

E-E
(PC35MR-1)
‘19
25 26
‘20

‘21 24

LL
E-E
(PC40MRs 45MR-1) 9JUOOO26

1. Lift check valve

2. Pressure compensation valve (float control 14. Pressure compensation valve (pressure reduc-
valve) (L.H.. travel) ing valve) (swing/breaker)
3. Unload valve 15. Pressure compensation valve (pressure reduc-
4. Unload valve ing valve) (bucket)
5. Pressure compensation valve (float control 16. Pressurecompensation valve (pressure reduc-
valve) (R.H.. travel) ing valve) (arm)
6. Throttle valve 17. Pressure compensation valve (pressure reduc-
7. Pressure compensation valve (float control ing valve) (boom)
valve) (boom) 18. Throttle valve
8. Pressure compensation valve (float control 19. Pressure compensation valve (pressure reduc-
valve) (arm) ing valve) (L.H.. travel)
9. Pressure compensation valve (float control 20. Unload valve
valve) (bucket) 21. Unload valve
10. Pressure compensation valve (float control 22. Pressure compensation valve (pressure reduc-
valve) (float control valve) (swing/breaker) ing valve) (R.H.. travel)
11. Swing relief valve (for gear pump) 23. Cooler bypass valve
12. Spool (breaker) 24. Spool (travel)
13. Pressure compensation valve (piston) (swing/ 25. Suction valve
breaker) 26. Suction valve

PC27 - 45MRX- 1 10-121

0
STRUCTURE AND FUNCTION CONTROL VALVE

10
F-F

6
EE-EE
(PC35MR-I)

a
10

9 EE-EE
13
G-G
(PC40MRs 45MR-1) 9JUOOO27

1. Unload valve 10. Spool (travel)

2. Check valve 11. Suction valve
3. Spool (junction valve) 12. Suction valve
4. Unload valve 13. Pressure compensation valve (pressure reduc-
5. Unload valve ing valve)
6. Check valve 14. Throttle valve
7. Main relief valve 15. Safety valve
8. Unload valve 16. LS bypass valve (LS3)
9. Pressure compensation valve (float control 17. LS pressure compensation valve
valve) 18. Throttle valve

1o-1 22 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION CONTROL VALVE

(5/6)

7
3

Ii 9JUOOO28

1. Pressure compensation valve (float control 13. Spool (arm)

valve) 14. Pilot pressure check valve
2. Spool (boom) 15. Suction valve
3. Suction valve 16. Check valve
4. Boom holding valve 17. Pressure compensation valve (pressure reduc-
5. Check valve .ing valve)
6. Check valve 18. Pressure compensation valve (float control
7. Suction valve valve)
8. Pressure compensation valve (pressure reduc- 19. Spool (bucket)
ing valve) 20. Suction valve
9. Logic valve 21. Check valve
10. Logic pressure bypass plug 22. Suction valve
11. LS bypass plug (LSI) 23. Pressure compensation valve (pressure reduc-
12. Pressure compensation valve (float control ing valve)
valve)

PC27 - 45MRX- 1 lo-123

0
STRUCTURE AND FUNCTION CONTROL VALVE

._
AA-AA

IO

N-N 9JUOOO29

1. Pressure compensation valve (float control 9. Suction

valve) 10. Check valve
2. Spool 11. Blade RAISE relief valve (with suction)
3. Suction valve mount 12. Spool (blade)
4. Check valve 13. Pilot pressure check valve
5. Suction valve 14. Spool
6. Pressure compensation valve (piston) 15. Swing relief valve (for gear pump)
7. Pressure compensation valve (pressure reduc- 16. Pilot pressure check valve
ing valve) 17. Air bleeding plug
8. Spool (breaker)

lo-124 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION SWING MOTOR

SWING MOTOR
PC27MRX, PC30MRX-1

MA

9Juooool

B : From control valve Specifications

S : From tank lType : LMFIG
T : To tank lTheoretical discharge : 16.1 cc/rev
MA : From control valve lRated speed : 1165 rpm
MB : From control valve lRated discharge amount : 18.8 Urnin
lsuction valve cracking pressure :
0.03 Mpa IO.30 kg/cm21
lSafety valve set pressure :
17.9 Mpa (184 kg/cm21

lo-126 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION SWING MOTOR

D-D

A-A c-c
SVP02837

1. Output shaft 9. Cylinder

2. Housing 10. Brake piston
3. Shoe 11. Swash plate
4. Piston 12. Brake spring
5. Center spring 13. Safety valve
6. Valve plate 14. Check valve
7. Disk 15. Check valve spring
8. Plate 16. Hydraulic timer valve

PC27 - 45Mf?X-1 lo-127

0
STRUCTURE AND FUNCTION SWING MOTOR

PC35MRX, PCNMRX, PC45MRX-1

9JUOOOO2

B : From control valve

S : From tank
MA : From control valve
MB : From control valve

lo-128 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION SWING MOTOR

ti ii lb i i i
B-0

A-A c-c
9JUOOOO3

1. Drive shaft 10. Brake piston

2. Housing 11. Swash plate
3. Shoe 12. Brake spring
4. Piston 13. Safety valve
5. Center spring 14. Check valve
6. Valve plate 15. Check valve spring
7. Disk 16. Hydraulic pressure timer valve
8. Plate 17. Plate
9. Cylinder

PC27 - 45MRX- 1 lo-129

0
STRUCTURE AND FUNCTION SWING MOTOR

SPECIFICATIONS

Model PC35MRX 1 PC40MRX 1 PC45MRX

l Tvoe LMF16
l Theoretical discharge (cc/rev) 16.1
l Rated speed @pm) 1266 1820
. Rated discharge amount (Urnin) 20.0 29.0
l suction valve cracking pressure (Mpa {kg/cm211 less than 0.04{0.45)
l Safety valve set pressure (Mpa {kg/cm21) 18.1{185} 20.1 I2051

HYDRAULIC MOTOR PORTION 3 1

1. Function
This hydraulic motor is a swash plate type
axial piston motor, which converts the hydrau-
lic force sent from the hydraulic pump to a
rotating movement.

2. Principle of operation
. The oil sent from the hydraulic pump goes
from valve plate (7) and enters cylinder block
(5).
. The structure of the motor takes in the oil at Y SXP07247

one side only of the Y-Y line joining the top

and bottom dead centers of the stroke of pis-
ton (4).
Y
. The pressure oil entering one side of cylinder
block (5) generates force Fl (FlNIkgI = P
MPa{kg/cm2} x ~r/4 D2cm2) pushing each pis-
ton (4) (3 or 4 pistons).
. This force acts on thrust plate (2), but thrust
plate (2) is secured at a certain angle a0 to out-
put shaft (I), so the force is divided into force
F2 and F3.
. Of the divided forces, the radial force F3 gen-
erates the torque (T = F3 x ri) for line Y - Y
joining the top and bottom dead centers. Y
SKP02839
The combined force of this torque Tr = IZ.(F3 x
ri)} goes as a rotating force through the pis-
ton to rotate cylinder block (5).
. Cylinder block (5) is joined to the output shaft
by a spline, so the output shaft rotates and
transmits the torque.

F3

10-130 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION SWING MOTOR

SAFETY VALVE PORTION

1. Outline
Safety valve portion (1) consists of a check
valve and safety valve. CA I
2. Function
. When the swing is stopped, the output circuit
of the motor is closed by the control valves,
but the motor continues to rotate because of
inertia. For this reason, the pressure at the
output side of the motor becomes abnormally
high, and this will damage the motor. To pre-
ventthis, the oil causing the abnormal hydrau-
lic pressure is allowed to escape from the
outlet port (high-pressure side) of the motor
to port S, thereby preventing damage to the
motor.

3. Operation
11 When starting swing
. When the swing control lever is operated to
left swing, the pressurized oil from the pump
passes through the control valves and is sup-
plied to port MB. Because of this, the pres-
sure at port MB rises, starting torque is gen-
erated in the motor, and the motor starts to
rotate. The oil from the outlet port of the mo-
tor passes from port MA through the control
valve and returns to the tank.
2) When stopping swing
. When the swing control lever is returned to
neutral, no pressurized oil is supplied from
the pump to port MB.
The return circuit to the tank is closed by the
control valve, so the pressure of the oil from
the outlet port of the motor increases at port
MA. Resistance to the rotation of the motor is
created, and the brake starts to act.
The pressure at port MA rises to the set pres-
sure of the safety valve, and in this way, a high
braking torque acts on the motor, and the
motor stops.
When the safety valve is being actuated, the
relief oil from the safety valve and the oil from
port S pass through check valve CB and are
supplied to port MB. This prevents cavitation
from occurring at port MB.

- SKP02842

PC27 - 45MRX- 1 10-131

0
STRUCTURE AND FUNCTION SWING MOTOR

OPERATION OF SWING BRAKE

1. PPC valve (swing, arm IN) at HOLD Swine Arm
l When the PPC valve (swing, arm IN) is at
HOLD, the PPC output pressure P is 0 MPa (0
kg/cm*).
l For this reason, brake piston (I) is pushed up
by brake spring (21, and disc (3) and plate (4)
are pushed together to apply the brake.

SXPO7248

2. PPC valve (swing, arm IN1 actuated

l When the PPC valve is actuated, PPC output Swine Arm
pressure P enters port B and flows to brake
chamber a.
The pressurized oil entering chamber a over-
comes brake spring (2) and pushes brake pis-
ton (I) down. As a result, disc (3) and plate (4)
separate and the brake is released.

SXPO7249

1O-l 32 PC27 - 45MRX-1

0
STRUCTURE AND FUNCTION SWING MOTOR

3. Actuation of hydraulic timer valve

. The hydraulic timer (16) acts to delay the start
of the swing brake effect in order to ensure
smooth deceleration and to prevent damage
to the parts of the motor if the swing brake is
applied suddenly when stopping the swing
motor.
. When the PPC valve (swing, arm IN) is actu-
ated, PPC output pressure P goes to chamber
a and the swing brake is released. In this con-
dition, if the PPC lever is returned to HOLD,
the supply of pressure oil to port B stops and
the pressure in chamber a drops. As a result,
the oil in chamber a is pushed out by brake
spring (2).
. There is a check valve in the PPC circuit at the
port B side, so the oil flow is stopped and it
flows out to passage c. However, the passage
A-A
of the flow is throttled by orifice (00.5) in the
hydraulic timer valve, so the oil inside cham-
ber a flows out only slowly, and this delays
the actuation of the swing brake by the deter-
SXPO7250
mined amount.

PC27 - 45MRX-1 10-133

0
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

PC27MRX-1

DRI

A-A

D2

DR2

SWPO6304

Al : To R.H. travel motor E2 : From blade control valve

B2 : To L.H. travel motor F2 : From blade control valve
Cl : To R.H. travel motor G2 : From travel Hi-Lo speed selector valve
Dl : To L.H. travel motor DR2:To tank
El : To blade cylinder bottom
Fl : To blade cylinder head 1. Cover
Gl : To travel Hi-Lo speed selector valve 2. Shaft
DRI : From travel motor drain port 3. Slipper seal
A2 : From R.H. travel control valve 4. Body
B2 : From L.H. travel control valve
C2 : From R.H. travel control valve
D2 : From L.H. travel control valve

10-134 PC27 - 45MRX-1

0
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT

PC30MWG1

,DR

Fl Dl Gl

Al

\ \
Bl DRl ‘255

A : From R.H. travel control valve Dl : To R.H. travel motor

B: From L.H. travel control valve El : To travel Hi-Lo speed selector valve
C : From R.H. travel control valve Fl : To blade cylinder head
D : From L.H. travel control valve Gl : To blade cylinder bottom
E : From travel Hi-Lo speed selector valve DRI : From travel motor drain port
F : From blade control valve
G: From blade control valve 1. Cover
DR : To tank 2. Shaft
Al : To L.H. travel motor 3. Body
Bl : To L.H. travel motor 4. Sliooer seal
Cl : To R.H. travel motor

PC27 - 45MRX- 1 1o-1 35

0
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT

PC35MRX, PC4OMRX, PC45MRX-1

A F 6 G

T D C

Gl

Bi

Dl

‘El

-4
A-A

Tl

9JA00709

A : From L.H. travel control valve Dl : To R.H. travel motor

B : From L.H. travel control valve El : To travel Hi-Lo speed selector valve
C : From R.H. travel control valve Fl : To blade cylinder head
D : From R.H. travel control valve Gl : To blade cylinder bottom
E : From travel Hi-Lo speed selector valve Tl : From travel motor drain port
F : From blade control valve
G : From blade control valve 1. Body
DR : To tank 2. Shaft
Al : To L.H. travel motor 3. Slipper seal
Bl : To L.H. travel motor 4. Cover
Cl : To R.H. travel motor

10-136 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION TRAVEL MOTOR

TRAVEL MOTOR
PC27MRX, PCBOMRX-1
This diagram shows PC30MRX.

OR A PP B DR

SWPO5257

A : From control valve

B : From control valve
DR : To tank
PP : From Travel speed Hi-Lo selector valve

lo-138 PC27 - 45MRX- 1

0
 TRAVEL MOTOR
STRUCTURE AND FUNCTION

7 SDP03025

1. Drain plug 13. Output shaft

14. No.1 sun gear
2. Cover
3. No.2 planetary gear 15. No.2 planetary carrier
4. Ring gear 16. No.2 sun gear
5. No.1 planetary gear 17. 2nd spool
6. Housing 18. Plug
7. Piston 19. Check valve
20. Check valve spring
8. Cylinder
21. Spool return spring
9. Valve plate
22. Check valve spring
10. Brake valve
23. Counterbalance valve spool
11. Center spring
12. Swash plate

1o-1 39
PC27 - 45MRX- 1
0
STRUCTURE AND FUNCTION TRAVEL MOTOR

PC35MRX, PC4OMRX-1
This diagram shows PC35MRX.

A-4 9JA01065

A : From control valve

B : From control valve
DR : To tank
PP : From Travel speed Hi-Lo selector valve

10-140 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION TRAVEL MOTOR

23

21 20 19 1’7 16 i5 i4 i3
A-A 9JA01064

1. Drain plug 15. Plate

2. Cover 16. Disk
3. No.2 planetary gear 17. Swash plate
4. Ring gear 18. Output shaft
5. No.1 planetary gear 19. No.1 sun gear
6. Bali 20. No.2 planetary carrier
7. Housing 21. No.2 sun gear
8. Piston 22. 2nd spool
9. Cylinder 23. Plug
10. Valve plate 24. Check valve
11. Spring 25. Plug
12. Brake valve 26. Spool return spring
13. Center spring 27. Check valve spring
14. Break piston 28. Counterbalance valve spool

PC27 - 45MRX- I 10-141

0
STRUCTURE AND FUNCTION SERVICE PPC VALVE

OPERATION. ”
1) At neutral
Ports A and B of the control valve and ports
PI and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool (I).

2) During fine control (neutral -+ fine control)

When piston (4) starts to be pushed by lever
(51, retainer (7) is pushed; spool (I) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is shut
off from drain chamber D, and at almost the
same time, it is connected to pump pressure
chamber PP, so pilot pressure oil from the
control pump passes through fine control hole
f and goes from port PI to port A.
When the pressure at portPI becomes higher,
spool (I) 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 PI. When this happens, spool (I) moves
SXPO77.69
up or down so that the force of metering
spring (2) is balanced with the pressure at port
PI. The relationship in the position of spool
(1) and body (IO) (fine control hole f is at a
point midway between drain hole D and pump
pressure chamber PP) does not change until
retainer (7) contacts spool (I 1.
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of
the control lever, so the pressure at port PI
also rises in proportion to the travel of the
control lever. In this way, the control valve
spool moves to a position where the pressure
in chamber A (the same as the pressure at
port PI) and the force of the control valve
spool return spring are balanced.

SXPO7270

PC27 - 45MRX- 1 lo-161

0
STRUCTURE AND FUNCTION SERVICE PPC VALVE

3) During fine control

(when control lever is returned)
When lever (5) starts to be returned, spool (I)
is pushed up by the force of centering spring
(3) and the pressure at port PI.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure
oil at port Pl is released.
If the pressure at port PI drops too far, spool
(I) is pushed down by metering spring (2),
and fine control hole f is shut off from drain
chamber PI. At almost the same time, it is
connected to pump pressure chamber PP, and
the pump pressure is supplied until the pres-
sure at port PI recovers to a pressure that
corresponds to the lever position.
When the spool of the control valve returns,
oil in drain chamber D flows in from fine con-
trol hole f’ in the valve on the side that is not
working. The oil passes through port P2 and
enters chamber B to fill the chamber with oil.

SXP07271

4) At full stroke
When lever (5) pushes down piston (4L and
retainer (9) pushes down spool (I), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP. Therefore, the pilot pressure from the
control pump passes through fine control hole
f and flows to chamber A from port PI, and
pushes the control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f’ and flows
to drain chamber D.

SXP07272

1O-l 62 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION WORK EQUIPMENT

WORK EQUIPMENT
This diagram shows PC30MRX.

IO SWPO6269

1. Bucket 6. Boom cylinder

2. Bucket cylinder 7. Boom swing cylinder
3. Arm 8. Boom swing bracket
4. Arm cylinder 9. Blade cylinder
5. Boom 10. Blade

PC27 - 45MRX-1 lo-163

0
STRUCTURE AND FUNCTION AIR CONDITIONER

AIR CONDITIONER
AIR CONDITIONER PIPING
This diagram shows PC30MRX.

SWPO5260

A : Fresh air 1. Receiver tank

B : Circulated air 2. Refrigerant piping
C : Hot air/cold air 3. Condenser
4. Hot water picking piping
5. Hot water return piping
6. Air conditioner compressor
7. Air conditioner unit
8. Duct

10-164 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM

PC35MRX-1

9JA00730

1. Working lamp 10. Engine oil pressure switch

2. Battery 11. Fuse box
3. Window washer tank 12. 2-stage solenoid valve
4. Fuel level sensor 13. Traveling accelerator pedal
5. Fusible link 14. Horn
6. Alternator 15. Timer
7. Coolant temperature sensor 16. Engine stop solenoid relay
8. Starting motor 17. Safety relay
9. Fuel feed pump 18. Engine stop solenoid

10-166 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM

PC40MRX, PC45MRX-1

9JA00731

1. Working lamp 10. Engine oil pressure switch

2. Horn 11. Fuse box
3. Battery 12. Traveling accelerator pedal
4. Window washer tank 13. Fuel level sensor
5. Fusible link 14. 2-stage solenoid valve
6. Alternator 15. Timer
7. Coolant temperature sensor 16. Safety relay
8. Starting motor 17. Engine stop solenoid relay
9. Fuel feed pump 18. Engine stop solenoid

PC27 - 45MRX- 1 lo-167

0
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

MACHINE MONITOR SYSTEM

Buzzer

6Rb

Buzzer signal
II

Sensor signal Snitch signal

Eeach
sensor Working
I amp
Heater (OP)

Power source

SXPO7274

FUNCTION
. The machine monitor system uses the net
work circuit between the controllers and sen-
sor installed to all parts of the machine to
observe the condition of the machine. It pro-
cesses this information, and display it on a
panel to inform the operator of condition of
the machine.
. The content of the information display on the
machine can broadly be divided as follows.

1. Monitor portion
This gives an alarm if any abnormality occurs
in the machine.
2. Gauge portion
This always display the coolant temperature
and fuel level.
. This monitor panel has various mode selec-
tor switches, and also functions as the con-
trol panel for the electronic control system.

10-170 PC27 - 45MRX- 1

a
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

MONITOR PANEL

F
a”
)Eb3
C ~~ F
&-m -

CN-Pl

SWPO5265

PC27 - 45MRX-1 10-171

0
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

Outline
l The monitor panel has a monitor displayfunc-
tion and gauge display function and service
meter display.
It has a built-in CPU (Central Processing Unit)
which processes the data and outputs the dis-
play.
A liquid crystal display is used for the gauge
display. Lamps are used for the monitor dis-
play.

lmut and output signal

NO.1 Name of sianal INo. N ame of sianal
1 Power source (+12V) 9 Engine oil pressure

2 - 10 Charge level

3 1GND II I I Electrical svstem

4 GND 12 -

5 Start signal 13 Preheat

6 I Coolant temDerature I 14 I -
7 I Fuel level 115 I Buzzer

8 - 16 Lamp

lo-172 PC27 - 45MRX- 1

0
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

MONITOR DISPLAY

6 5 4 9JA00736

-
Display
No. Display item Display range Display method Color remarks
category
-
Count time when engine is running (When _ t lisplay the
1 Service meter Oto ggggg.gh generating electricity by alternator) C lock time
f
- J_

One lamp lights up to show the temperature

Refer to upper (When the lamp at the highest level (above
2 105’C) lights up, the segment flashes and the
r:ure frawing 1 buzzer sounds) 1 B,ue
- Gauges LED
One lamp lights up to show the level
3 ~$wi~gUpper (When the lamp at the lowest level (empty)
lights up, the segment flashes)
-
When the starting switch is at HEAT, lamp is
When
4 Pilot Preheating ON (18 set); after this it goes OFF to indicate Green Lamp
preheating completion of preheating
-

When the starting switch ON with the engine

5 running, the display is as follows:
- Normal : OFF Red
Caution Lamp
Abnormal : ON
(Buzzer sounds if abnormality occurswhen
6 engine is running)
-

PC27 - 45MRX- 1 10-173

0
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

SENSOR
l The sensor from the sensors are input directly to monitor panel.
l The contact type sensors are always connected at one end to the chassis GND.

Category of display Type of sensor Sensor method When normal When abnormal

Caution Engine oil pressure Contact type OFF (open) ON (closed)

Coolant temperature Resistance type - -

Gauges
Fuel level Resistance type - -

ENGINE OIL LEVEL SENSOR

@
0 @ Structure
of circuit

SXPO7255

1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal

COOLANT TEMPERATURE SENSOR

Structure
of circuit

SXPO7256

1. Connector
2. Plug
3. Thermistor

10-174 PC27 - 45MRX-1

0
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

FUEL LEVEL SENSOR

PC27MRX, PC30MRX, PC35MRX-1

FULL

Structure
of circuit

F--
I
: 1
i

f
I I

EMPTY

-t
2

SXP07277

1. Float
2. Connector
3. Bracket
4. Variable resistor

PC27 - 45MRX-1 10-175

0
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

PC40MRX, PC45MRX-1

Structure
of circuit

EMPTY
SXPO7278

1. Float
2. Connector
3. Bracket
4. Variable resistor

lo-176 PC27 - 45MRX-1

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Applicable model PC27MRX-1

Engine 3D82EA-3H

Standard value Service limit

Item Measurement conditions Unit for new machine value

High idling rpm 2,785 ± 50 —

Engine speed Low idling rpm 1,050 ± 50 —

Rated speed rpm 2,600 —

Bosch
At sudden acceleration index Max. 5.5 7.5
Exhaust gas color
Bosch
At high idling index Max. 1.0 2.0

Intake valve mm 0.20 —

Valve clearance
(Normal temperature)
Exhaust valve mm 0.20 —

MPa 3.04 2.45

Compression pressure Oil temperature: 40 – 60°C {kg/cm2} {31} {25}

(SAE30 oil) (engine speed: 250rpm)

Blow-by pressure (Water temperature: Operating range) Pa — —

(SAE30 oil) At high idling {mmH2O} {—} {—}

(Water temperature: Operating range)

MPa 0.294 – 0.461 Min. 0.2

At high idling {kg/cm2} {3.0 – 4.7} {Min. 2.0}
Oil pressure
(SAE30 oil) MPa Min. 0.15 Min. 0.1
At low idling (SAE30) {kg/cm2} {Min. 1.5} {Min. 1.0}

MPa Min. 0.15 Min. 0.1

At low idling (SAE10W) {kg/cm2} {Min. 1.5} {Min. 1.0}

Oil temperature Whole speed range (inside oil pan) °C Max. 120 Max. 120

Fuel injection timing Before compression top dead center deg. 14 ± 1 —

Deflection when pressed with finger

Fan belt tension force of approx. 58.8 N {6 kg} mm 10 – 15 —

20-2 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Applicable model PC30MRX-1

Engine 3D84E-3EK

Standard value Service limit

Item Measurement conditions Unit for new machine value

High idling rpm 2,650 ± 50 —

Engine speed Low idling rpm 1,110 ± 50 —

Rated speed rpm 2,500 —

Bosch
At sudden acceleration index Max. 3.5 5.5
Exhaust gas color
Bosch
At high idling index Max. 1.0 2.0

Intake valve mm 0.20 —

Valve clearance
(Normal temperature)
Exhaust valve mm 0.20 —

MPa 2.94 2.55

Compression pressure Oil temperature: 40 – 60°C {kg/cm2} {30} {26}

(SAE30 oil) (engine speed: 250rpm)

Blow-by pressure (Water temperature: Operating range) Pa — —

(SAE30 oil) At high idling {mmH2O} {—} {—}

(Water temperature: Operating range)

MPa 0.3 – 3.4 Min. 0.2

At high idling {kg/cm2} {3.0 – 3.5} {Min. 2.0}
Oil pressure
(SAE30 oil) MPa Min. 0.15 Min. 0.1
At low idling (SAE30) {kg/cm2} {Min. 1.5} {Min. 1.0}

MPa Min. 0.15 Min. 0.1

At low idling (SAE10W) {kg/cm2} {Min. 1.5} {Min. 1.0}

Oil temperature Whole speed range (inside oil pan) °C Max. 120 Max. 120

Fuel injection timing Before compression top dead center deg. 14 ± 1 —

Deflection when pressed with finger

Fan belt tension force of approx. 58.8 N {6 kg} mm 10 – 15 —

PC27 – 45MRX-1 20-3

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC27MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value
• Engine at full throttle 15.68 ± 4.9 15.68 ± 4.9
Boom control lever • Oil temperature: 45 – 55°C {1.6 ± 0.5} {1.6 ± 0.5}
• Fit push-pull scale to center of control
lever knob to measure 15.68 ± 4.9 15.68 ± 4.9
Arm control lever • Fit push-pull scale to tip of pedal to {1.6 ± 0.5} {1.6 ± 0.5}
measure
Operating effort of control levers

• Measure max. value to end of travel 15.68 ± 4.9 15.68 ± 4.9

Bucket control lever {1.6 ± 0.5} {1.6 ± 0.5}

15.68 ± 4.9 15.68 ± 4.9

Swing control lever {1.6 ± 0.5} {1.6 ± 0.5}

N 51.9 ± 12.7 51.9 ± 12.7

Boom swing control pedal {kg} {5.3 ±1.5} {5.3 ±1.5}

31.4 ± 9.8 31.4 ± 9.8

Blade control lever {3.2 ± 1.0} {3.2 ± 1.0}

17.64 ± 3.92 17.64 ± 3.92

Travel control lever {1.8 ± 0.4} {1.8 ± 0.4}

29.4 ±14.7 29.4 ±14.7

Min. → Max. {3.0 ± 1.5} {3.0 ± 1.5}
Fuel control lever
29.4 ±14.7 29.4 ±14.7
Max. → Min. {3.0 ± 1.5} {3.0 ± 1.5}
• Oil temperature: 45 – 55°C
• Engine at full throttle 4.41 ± 0.49 4.41 ± 0.49
Unload pressure • All levers at neutral {45 ± 5} {45 ± 5}
• Pump outlet port pressure
• Oil temperature: 45 – 55°C 22.06 ± 0.49 22.06 ± 0.49
Boom {225 ± 5} {225 ± 5}
• Engine at full throttle
• Pump outlet port pressure
• Relieve only circuit to be measured 22.06 ± 0.49 22.06 ± 0.49
Arm {225 ± 5} {225 ± 5}

22.06 ± 0.49 22.06 ± 0.49

Bucket {225 ± 5} {225 ± 5}

18.0 ␣ +0.49
0 18.0 ␣+0.49
0
Swing {184␣ +50 } {184␣ +50 }
Hydraulic pressure

22.06 ± 0.49 22.06 ± 0.49

Boom swing {225 ± 5} {225 ± 5}
MPa Raise Raise
{kg/ 16.2 ± 0.49 16.2 ± 0.49
Blade cm2} {165 ± 5} {165 ± 5}
Lower Lower
21.6 ± 0.49 21.6 ± 0.49
{220 ± 5} {220 ± 5}
22.06 ± 0.49 22.06 ± 0.49
Travel {225 ± 5} {225 ± 5}

12.94 +0.49
␣
–0.1 12.94 +0.49
␣
–0.1
Control pump {30␣ +5 {30␣ +5
–1 } –1 }

• Oil temperature: 45 – All levers at 4.41 ± 0.49 4.41 ± 0.49

55°C hold {45 ± 5} {45 ± 5}
• Engine at full throttle
LS differential pressure flLS differential Travel under
pressure = Pump no load, travel 1.57 ± 0.1 1.57 ± 0.1
outlet port pressure lever at half- {16 ± 1} {16 ± 1}
– LS pressure way position

PC27 – 45MRX-1 20-7

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC27MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

See Fig. C
• Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
Overrun when stopping • Stop after swinging one turn and deg. Max. 30 40
swing measure distance that swing circle (mm) (—) (—)
moves
( ): Distance of movement on outside
circumference of swing circle

See Fig. C 90˚ 2.1 ± 0.3 2.8

Time taken to start Sec.

swing • Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
• Time taken to swing 90° and 180˚ — —
180° from starting position

See Fig. C
Swing

Time taken to swing

• Engine at full throttle Sec. 32 ± 3 37
• Hydraulic oil temperature: 45 – 55˚C
• Swing one turn, then measure time
taken to swing next 5 turns

See Fig. D Rated load:

1,236 N {126 kg}
• Engine stopped
• Hydraulic oil temperature: 45 – 55°C
• Bucket at rated load or fully loaded deg.
with soil 0 0
Hydraulic drift of swing (mm) (0) (0)
• Set machine on 15° slope with upper
structure at 45° to front.
• Make counter marks on swing circle
outer race and track frame.
• Measure distance that counter marks
move apart after 15 minutes.

• Engine at full throttle cc/

Leakage from swing • Hydraulic oil temperature: 45 – 55°C — —
motor mim
• Relieve swing circuit.

20-8 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC27MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

Low 31 ± 2 31 ± 4
See Fig. R speed

Travel speed (1) • Engine at full throttle Sec.

• Hydraulic oil temperature: 45 – 55°C
• Raise track on one side at a time, High
rotate one turn, then measure time speed 15.8 ± 2 16 ± 4
taken for next 5 turns under no load.

Low 29.5 ± 2 29.5 ± 4

See Fig. E speed (30.4 ± 2) (30.4 ± 4)

Travel speed (2) • Engine at full throttle Sec.

• Hydraulic oil temperature: 45 – 55°C
• Run up for at least 10 m, and
measure time taken to travel next 20 High 15.0 ± 2 15.0 ± 4
m on flat ground. speed (15.4 ± 2) (15.4 ± 4)
• ( ): Steel shoe specification machine

See Fig. E
Travel

See Fig. E
Low speed: Low speed: 550
Travel deviation • Engine at full throttle mm Max. 500
• Hydraulic oil temperature: 45 – 55°C High speed: High speed: 330
• Run up for at least 10 m, and measure Max. 300
deviation when traveling next 20 m on flat
ground.
• Use a hard horizontal surface.

See Fig. G
Hydraulic drift of
travel • Engine stopped
• Hydraulic oil temperature: 45 – 55°C mm Max. 200 Max. 240
• Stop machine on 30° slope with sprocket
facing straight up the slope.
• Measure the distance the machine moves
in 5 minutes.

Leakage of travel • Engine at full throttle

• Hydraulic oil temperature: 45 – 55°C ¬/ — —
motor mm
• Lock shoes and relieve travel circuit.

PC27 – 45MRX-1 20-9

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC27MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value
Total work Rated load:
equipment 1,236N {126 kg}

 hydraulic drift 
 at tip of bucket  See Fig. H Max. 250 Max. 275
 teeth 

Boom cylinder • Place in above

posture and mea-
 amount of  sure extension or
 retraction of  retraction of each
 cylinder
 cylinder and
downward move-
Max. 20 Max. 30

ment at tip of bucket

teeth.
• Horizontal, flat
ground
Arm cylinder • Bucket: Rated load
• Levers at neutral
 amount of  • Engine stopped
 extension of  • Hydraulic oil
 cylinder
 temperature: 45 –
55°C
Max. 20 Max. 30

• Start measuring
immediately after
setting.
Work equipment

• Measure hydraulic
Bucket cylinder drift every 5 min-
Hydraulic drift of utes, and judge
work equipment  amount of  from results for 15 mm
 retraction of  minutes.
 cylinder  Max. 20 Max. 30

Boom swing • Engine stopped

cylinder • Hydraulic oil
temperature: 45 –
 amount of
retraction,  55°C
• Bucket: Rated load
 extension of  • Place in same
 cylinder  posture as above on
15° slope with upper Max.15 Max. 23
structure facing 90°
to side, and mea-
sure extension or
retraction of
cylinder for 15
minutes

Blade • Engine stopped

• Hydraulic oil
 downward  temperature: 45 –
 movement at  55°C
 tip of blade  • Raise blade fully,
and measure Max. 30 Max. 45
downward move-
ment at cutting edge
of blade for 15
minutes

20-10 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC27MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

See Fig. N
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Retract arm, boom
cylinders fully and set
Boom boom at max. height. Max. 2 Max. 2
Lower boom and
measure time taken
from point where
bucket contacts
ground to point where
chassis rises from
ground

See Fig. O
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Arm horizontal and retract Max. 1 Max. 1
bucket cylinder fully.
Then extend cylinder
and measure time
taken for arm to stop
Work equipment

at bottom and then

start again
Time lag Sec.
See Fig. P
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Bucket horizontal and retract Max. 1 Max. 1
arm cylinder fully.
Then extend cylinder
and measure time
taken for bucket to
stop at bottom and
then start again

See Fig. Q
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Raise blade to max.
height. Then lower
Blade boom and measure Max. 2 Max. 2
time taken from point
where blade contacts
ground to point where
chassis rises from
ground

• Hydraulic oil tem-

Each cylinders perature: 45 – 55°C Max. 2 10
cc/
Internal leakage • Engine at full throttle mm
Center swivel • Relieve circuit to be
joint measured — —

20-12 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

MACHINE MODEL: PC30MRX-1

Applicable model PC30MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value
• Hydraulic oil temperature: 45 – 55°C
Engine speed

At 1-pump relief • Engine oil pressure: Within operating Min. 2,500 Min. 2,500
range
• Engine water temperature: Within rpm
operating range
At 2-pump relief • 1-pump relief: Bucket relief Min. 2,060 Min. 2,060
• 2-pump relief: Bucket + swing relief
¬ a b ¬ a b
Boom control valve

Arm control valve

Bucket control valve See Fig. A 30 6 6 30 6 6

Swing control valve

Spool stroke

Breaker control valve mm

Boom swing control valve

Blade control valve

See Fig. B 20 6 6 20 6 6
L.H. travel control valve

R.H. travel control valve

• Center of
Boom control lever lever knob N → RAISE, LOWER 95 ± 10 95 ± 10
• Tip of pedal
• Read max.
Arm control lever value to end N → CURL, DUMP 95 ± 10 95 ± 10
of travel
• Engine
Bucket control lever stopped N → CURL, DUMP 95 ± 10 95 ± 10
Travel of control levers stroke

Swing control lever N → Left, right swing 95 ± 10 95 ± 10

Boom swing control pedal N → Left, right boom swing 25 ± 5 25 ± 5

mm
Blade control lever N → RAISE, LOWER 50 ± 5 50 ± 5

N → FORWARD, RE-
Travel control lever VERSE (left, right) 85 ± 10 85 ± 10

Fuel control lever Min. ←→ Max. 110 ± 20 110 ± 20

Work equipment, swing Max. 5 Max. 5

Play of control lever
Travel Max. 35 Max. 35

PC27 – 45MRX-1 20-13

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC30MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value
• Engine at full throttle 15.68 ± 4.9 15.68 ± 4.9
Boom control lever • Oil temperature: 45 – 55°C {1.6 ± 0.5} {1.6 ± 0.5}
• Fit push-pull scale to center of control
lever knob to measure 15.68 ± 4.9 15.68 ± 4.9
Arm control lever • Fit push-pull scale to tip of pedal to {1.6 ± 0.5} {1.6 ± 0.5}
measure
Operating effort of control levers

• Measure max. value to end of travel 15.68 ± 4.9 15.68 ± 4.9

Bucket control lever {1.6 ± 0.5} {1.6 ± 0.5}

15.68 ± 4.9 15.68 ± 4.9

Swing control lever {1.6 ± 0.5} {1.6 ± 0.5}

N 51.9 ± 12.7 51.9 ± 12.7

Boom swing control pedal {kg} {5.3 ±1.5} {5.3 ±1.5}

31.4 ± 9.8 31.4 ± 9.8

Blade control lever {3.2 ± 1.0} {3.2 ± 1.0}

17.64 ± 3.92 17.64 ± 3.92

Travel control lever {1.8 ± 0.4} {1.8 ± 0.4}

29.4 ±14.7 29.4 ±14.7

Min. → Max. {3.0 ± 1.5} {3.0 ± 1.5}
Fuel control lever
29.4 ±14.7 29.4 ±14.7
Max. → Min. {3.0 ± 1.5} {3.0 ± 1.5}
• Oil temperature: 45 – 55°C
• Engine at full throttle 4.41 ± 0.49 4.41 ± 0.49
Unload pressure • All levers at neutral {45 ± 5} {45 ± 5}
• Pump outlet port pressure
• Oil temperature: 45 – 55°C 25.5 ± 0.49 25.5 ± 0.49
Boom {260 ± 5} {260 ± 5}
• Engine at full throttle
• Pump outlet port pressure
• Relieve only circuit to be measured 25.5 ± 0.49 25.5 ± 0.49
Arm {260 ± 5} {260 ± 5}

25.5 ± 0.49 25.5 ± 0.49

Bucket {260 ± 5} {260 ± 5}

18.0 ␣ +0.49
0 18.0 +0.49
␣0
Swing {184␣ +50 } {184␣ +50 }
Hydraulic pressure

25.5 ± 0.49 25.5 ± 0.49

Boom swing {260 ± 5} {260 ± 5}
MPa Raise Raise
{kg/ 16.2 ± 0.49 16.2 ± 0.49
Blade cm2} {165 ± 5} {165 ± 5}
Lower Lower
21.6 ± 0.49 21.6 ± 0.49
{220 ± 5} {220 ± 5}
25.5 ± 0.49 25.5 ± 0.49
Travel {260 ± 5} {260 ± 5}

2.94 ␣ +0.49
–0.1 2.94 +0.49
␣
–0.1
Control pump {30␣ +5 {30␣ +5
–1 } –1 }

• Oil temperature: 45 – All levers at 4.41 ± 0.49 4.41 ± 0.49

55°C hold {45 ± 5} {45 ± 5}
• Engine at full throttle
LS differential pressure flLS differential Travel under
pressure = Pump no load, travel 1.57 ± 0.1 1.57 ± 0.1
outlet port pressure lever at half- {16 ± 1} {16 ± 1}
– LS pressure way position

20-14 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC30MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

See Fig. C
• Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
Overrun when stopping • Stop after swinging one turn and deg. Max. 40 50
swing measure distance that swing circle (mm) (—) (—)
moves
( ): Distance of movement on outside
circumference of swing circle

See Fig. C 90˚ 2.3 ± 0.3 2.9

Time taken to start Sec.

swing • Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
• Time taken to swing 90° and 180˚ — —
180° from starting position

See Fig. C
Swing

Time taken to swing • Engine at full throttle Sec. 32 ± 3 38

• Hydraulic oil temperature: 45 – 55˚C
• Swing one turn, then measure time
taken to swing next 5 turns

See Fig. D Rated load:

1,422 N {145 kg}
• Engine stopped
• Hydraulic oil temperature: 45 – 55°C
• Bucket at rated load or fully loaded
Hydraulic drift of swing with soil deg. 0 0
• Set machine on 15° slope with upper (mm) (0) (0)
structure at 45° to front.
• Make counter marks on swing circle
outer race and track frame.
• Measure distance that counter marks
move apart after 15 minutes.

Leakage from swing • Engine at full throttle

• Hydraulic oil temperature: 45 – 55°C cc/ — —
motor mim
• Relieve swing circuit.

PC27 – 45MRX-1 20-15

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC30MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

Low 28.4 ± 2 29 ± 4
See Fig. R speed

Travel speed (1) • Engine at full throttle Sec.

• Hydraulic oil temperature: 45 – 55°C
• Raise track on one side at a time, High 19.3 ± 2 18 ± 4
rotate one turn, then measure time speed
taken for next 5 turns under no load.

See Fig. E Low 25.7 ± 2 25.7 ± 4

speed (26.5 ± 2) (26.5 ± 4)

Travel speed (2) • Engine at full throttle Sec.

• Hydraulic oil temperature: 45 – 55°C
• Run up for at least 10 m, and
measure time taken to travel next 20 High 15.7 ± 2 15.7 ± 4
m on flat ground. speed (16.2 ± 2) (16.2 ± 4)
• ( ): Steel shoe specification machine

See Fig. E
Travel

See Fig. F
Low speed: Low speed: 550
• Engine at full throttle Max. 500
Travel deviation • Hydraulic oil temperature: 45 – 55°C mm High speed: High speed: 330
• Run up for at least 10 m, and measure Max. 300
deviation when traveling next 20 m on flat
ground.
• Use a hard horizontal surface.

See Fig. G

Hydraulic drift of • Engine stopped

travel • Hydraulic oil temperature: 45 – 55°C mm Max. 300 330
• Stop machine on 30° slope with sprocket
facing straight up the slope.
• Measure the distance the machine moves
in 5 minutes.

• Engine at full throttle

Leakage of travel • Hydraulic oil temperature: 45 – 55°C ¬/ — —
motor • Lock shoes and relieve travel circuit. mm

20-16 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC30MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value
Total work Rated load:
equipment 1,422N {145 kg}

 hydraulic drift 
 at tip of bucket  See Fig. H Max. 300 450
 teeth 

Boom cylinder • Place in above

posture and mea-
 amount of  sure extension or
 retraction of  retraction of each
 cylinder
 cylinder and
downward move-
Max. 20 Max. 30

ment at tip of bucket

teeth.
• Horizontal, flat
ground
Arm cylinder • Bucket: Rated load
• Levers at neutral
 amount of  • Engine stopped
 extension of  • Hydraulic oil
 cylinder
 temperature: 45 –
55°C
Max. 20 Max. 30

• Start measuring
immediately after
setting.
Work equipment

• Measure hydraulic
Bucket cylinder drift every 5 min-
Hydraulic drift of utes, and judge
work equipment  amount of  from results for 15 mm
 retraction of  minutes.
 cylinder  Max. 20 30

Boom swing • Engine stopped

cylinder • Hydraulic oil
temperature: 45 –
 amount of
retraction,  55°C
• Bucket: Rated load
 extension of  • Place in same
 cylinder  posture as above on
15° slope with upper Max. 20 30
structure facing 90°
to side, and mea-
sure extension or
retraction of
cylinder for 15
minutes

Blade • Engine stopped

• Hydraulic oil
 downward  temperature: 45 –
 movement at  55°C
 tip of blade  • Raise blade fully,
and measure Max. 30 45
downward move-
ment at cutting edge
of blade for 15
minutes

PC27 – 45MRX-1 20-17

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC30MRX-1

Cat- Standard value Service limit

egory Item Measurement conditions Unit for new machine value
Boom

RAISE
Bucket teeth in 2.7 ± 0.3 2.7 ± 0.6
contact with See Fig. I
ground

↑
↓ • Engine at full throttle

LOWER
• Hydraulic oil tempera-
ture: 45 – 55°C 2.7 ± 0.3 2.7 ± 0.6
Cylinder fully
extended

Arm

CURL
Cylinder fully 3.0 ± 0.3 3.0 ± 0.3
retracted See Fig. J

↑ • Engine at full throttle

↓
DUMP

• Hydraulic oil tempera-

ture: 45 – 55°C 2.7 ± 0.3 2.7 ± 0.6

Fully extended
Bucket
CURL
Work equipment

Cylinder fully 2.4 ± 0.3 2.4 ± 0.3

retracted See Fig. K
Work equipment sec.
speed ↑
↓ • Engine at full throttle
DUMP

• Hydraulic oil tempera-

ture: 45 – 55°C 1.9 ± 0.3 1.9 ± 0.6
Fully extended
Blade
RAISE

Blade in contact 1.7 ± 0.3 1.7 ± 0.6

with ground See Fig. L

↑
↓ • Engine at full throttle
LOWER

• Hydraulic oil tempera-

ture: 45 – 55°C 1.9 ± 0.3 1.9 ± 0.6
Blade fully raised

Boom swing
Right swing Left swing

Cylinder fully 7.5 ± 1.5 7.5 ± 3.0

retracted See Fig. M

↑
↓ • Engine at full throttle
• Hydraulic oil tempera-
ture: 45 – 55°C 7.5 ± 1.5 7.5 ± 3.0
Fully extended

20-18 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC30MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

See Fig. N
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Retract arm, boom
cylinders fully and set
Boom boom at max. height. Max. 2 Max. 2
Lower boom and
measure time taken
from point where
bucket contacts
ground to point where
chassis rises from
ground

See Fig. O
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Arm horizontal and retract Max. 1 Max. 1
bucket cylinder fully.
Then extend cylinder
and measure time
taken for arm to stop
Work equipment

at bottom and then

start again
Time lag Sec.
See Fig. P
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Bucket horizontal and retract Max. 1 Max. 1
arm cylinder fully.
Then extend cylinder
and measure time
taken for bucket to
stop at bottom and
then start again

See Fig. Q
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Raise blade to max.
height. Then lower
Blade boom and measure Max. 2 Max. 2
time taken from point
where blade contacts
ground to point where
chassis rises from
ground

• Hydraulic oil tem-

Each cylinders perature: 45 – 55°C Max. 2 10
cc/
Internal leakage • Engine at full throttle mm
Center swivel • Relieve circuit to be
joint measured — —

PC27 – 45MRX-1 20-19

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

MACHINE MODEL: PC35MRX-1

Applicable model PC35MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value
• Hydraulic oil temperature: 45 – 55°C
Engine speed

At 1-pump relief • Engine oil pressure: Within operating Min. 2,060 Min. 2,060
range
• Engine water temperature: Within rpm
operating range
At 2-pump relief • 1-pump relief: Bucket relief Min. 2,060 Min. 2,060
• 2-pump relief: Bucket + swing relief
¬ a b ¬ a b
Boom control valve

Arm control valve

Bucket control valve See Fig. A 30 6 6 30 6 6

Swing control valve

Spool stroke

Breaker control valve mm

Boom swing control valve

Blade control valve

See Fig. B 20 6 6 20 6 6
L.H. travel control valve

R.H. travel control valve

• Center of
Boom control lever lever knob N → RAISE, LOWER 95 ± 10 95 ± 10
• Tip of pedal
• Read max.
Arm control lever value to end N → CURL, DUMP 95 ± 10 95 ± 10
of travel
• Engine
Bucket control lever stopped N → CURL, DUMP 95 ± 10 95 ± 10
Travel of control levers stroke

Swing control lever N → Left, right swing 95 ± 10 95 ± 10

Boom swing control pedal N → Left, right boom swing 25 ± 5 25 ± 5

mm
Blade control lever N → RAISE, LOWER 50 ± 5 50 ± 5

N → FORWARD, RE-
Travel control lever VERSE (left, right) 75 ± 10 75 ± 10

Fuel control lever Min. ←→ Max. 110 ± 10 110 ± 10

Work equipment, swing Max. 5 Max. 5

Play of control lever
Travel Max. 35 Max. 35

20-20 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC35MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value
• Engine at full throttle 15.68 ± 4.9 15.68 ± 9.8
Boom control lever • Oil temperature: 45 – 55°C {1.6 ± 0.5} {1.6 ± 1}
• Fit push-pull scale to center of control
lever knob to measure 15.68 ± 4.9 15.68 ± 9.8
Arm control lever • Fit push-pull scale to tip of pedal to {1.6 ± 0.5} {1.6 ± 1}
measure
Operating effort of control levers

• Measure max. value to end of travel 15.68 ± 4.9 15.68 ± 9.8

Bucket control lever {1.6 ± 0.5} {1.6 ± 1}

15.68 ± 4.9 15.68 ± 9.8

Swing control lever {1.6 ± 0.5} {1.6 ± 1}

N 49 ± 14.7 49 ± 29.4
Boom swing control pedal {kg} {5 ±1.5} {5 ± 3}

27.44 ± 3.92 27.44 ± 7.84

Blade control lever {2.8 ± 0.4} {2.8 ± 0.8}

17.64 ± 3.92 17.64 ± 7.84

Travel control lever {1.8 ± 0.4} {1.8 ± 0.8}

53.9 ± 29.4 53.9 ± 39.2

Min. → Max. {5.5 ± 3} {5.5 ± 4}
Fuel control lever
53.9 ± 29.4 53.9 ± 39.2
Max. → Min. {5.5 ± 3} {5.5 ± 4}
• Oil temperature: 45 – 55°C
• Engine at full throttle 3.2 ± 0.49 3.2 ± 0.49
Unload pressure • All levers at neutral {33± 5} {33± 5}
• Pump outlet port pressure
• Oil temperature: 45 – 55°C 26.3 ± 0.49 26.3 ± 0.49
Boom {268 ± 5} {268 ± 5}
• Engine at full throttle
• Pump outlet port pressure
• Relieve only circuit to be measured 26.3 ± 0.49 26.3 ± 0.49
Arm {268 ± 5} {268 ± 5}

26.3 ± 0.49 26.3 ± 0.49

Bucket {268 ± 5} {268 ± 5}

18.6 ± 0.98 18.6 ± 0.98

Swing {190 ± 10} {190 ± 10}
Hydraulic pressure

26.3 ± 0.49 26.3 ± 0.49

Boom swing {268 ± 5} {268 ± 5}
MPa Raise Raise
{kg/ 17.2 ± 0.49 17.2 ± 0.49
Blade cm2} {175 ± 5} {175 ± 5}
Lower Lower
21.6 ± 0.49 21.6 ± 0.49
{220 ± 5} {220 ± 5}
26.3 ± 0.49 26.3 ± 0.49
Travel {268 ± 5} {268 ± 5}

2.94 (2.93 – 3.43) 2.94 (2.93 – 3.43)

Control pump {30 (29 – 35)} {30 (29 – 35)}
• Oil temperature: 45 – All levers at 3.2 ± 0.49 3.2 ± 0.49
55°C hold {33 ± 5} {33 ± 5}
• Engine at full throttle
LS differential pressure flLS differential Travel under
pressure = Pump no load, travel 1.57 ± 0.1 1.57 ± 0.1
outlet port pressure lever at half- {16 ± 1} {16 ± 1}
– LS pressure way position

PC27 – 45MRX-1 20-21

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC35MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

See Fig. C
• Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
Overrun when stopping • Stop after swinging one turn and deg. Max. 40 50
swing measure distance that swing circle (mm) (—) (—)
moves
( ): Distance of movement on outside
circumference of swing circle

See Fig. C 3.1 ± 0.3 3.7

90˚
Time taken to start • Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C Sec.
swing
• Time taken to swing 90° and 180˚ — —
180° from starting position
See Fig. C
• Engine at full throttle
Swing

Time taken to swing • Hydraulic oil temperature: 45 – 55˚C Sec. 33 ± 4 41

• Swing one turn, then measure time
taken to swing next 5 turns

See Fig. D
• Engine stopped Rated load:
• Hydraulic oil temperature: 45 – 55°C 1,765 N {180 kg}
• Bucket at rated load or fully loaded
with soil deg. 0 0
Hydraulic drift of swing • Set machine on 15° slope with upper (mm) (0) (0)
structure at 45° to front.
• Make counter marks on swing circle
outer race and track frame.
• Measure distance that counter marks
move apart after 15 minutes.

Leakage from swing • Engine at full throttle cc/

motor • Hydraulic oil temperature: 45 – 55°C mim — —
• Relieve swing circuit.

See Fig. E
Low 25.7 ± 2 25.7 ± 4
• Engine at full throttle speed (26.5 ± 2) (26.5 ± 4)
• Hydraulic oil temperature: 45 –
Travel speed 55°C Sec.
• Run up for at least 10 m, and
measure time taken to travel
next 20 m on flat ground. High 15.7 ± 2 15.7 ± 4
• ( ): Steel shoe specification speed (16.2 ± 2) (16.2 ± 4)
machine
Travel

See Fig. E

See Fig. F
Low speed: Low speed: 550
Max. 500
Travel deviation • Engine at full throttle mm High speed: High speed: 330
• Hydraulic oil temperature: 45 – 55°C Max. 300
• Run up for at least 10 m, and measure
deviation when traveling next 20 m
on flat ground.
• Use a hard horizontal surface.

20-22 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC35MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

See Fig. G

Hydraulic drift of • Engine stopped mm 0 0

travel • Hydraulic oil temperature: 45 – 55°C
Travel

• Stop machine on 30° slope with sprocket

facing straight up the slope.
• Measure the distance the machine
moves in 5 minutes.

Leakage of travel • Engine at full throttle ¬/

motor • Hydraulic oil temperature: 45 – 55°C mm — —
• Lock shoes and relieve travel circuit.

Total work See Fig. H Rated load:

equipment 1,765{180 kg}

 hydraulic drift  Max. 300 450

 at tip of bucket 
 teeth  • Place in above
posture and measure
Boom cylinder extension or retrac-
tion of each cylinder
 amount of  and downward
6 9
 retraction of  movement at tip of
 cylinder
 bucket teeth.
• Horizontal, flat
ground
Arm cylinder • Bucket: Rated load
• Levers at neutral
 amount of  • Engine stopped mm
27 41
 extension of  • Hydraulic oil tem-
 cylinder
 perature: 45 – 55°C
• Start measuring
immediately after
Work equipment

Bucket cylinder setting.

• Measure hydraulic
Hydraulic drift of  amount of  drift every 5 minutes,
17 26
work equipment  retraction of  and judge from
 cylinder  results for 15
minutes.

Boom swing • Engine stopped

cylinder • Hydraulic oil tem-
perature: 45 – 55°C
 amount of
retraction,  • Bucket: Rated load
• Place in same
 extension of  posture as above on
 cylinder  15° slope with upper Max.20 30
structure facing 90°
to side, and measure
extension or retrac-
tion of cylinder for 15
minutes

Blade • Engine stopped

• Hydraulic oil tem-
 downward  perature: 45 – 55°C
 movement at  • Raise blade fully, and
Max.30 45
 tip of blade  measure downward
movement at cutting
edge of blade for 15
minutes

PC27 – 45MRX-1 20-23

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC35MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

See Fig. N
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Retract arm, boom
cylinders fully and set
Boom boom at max. height. Max. 2 Max. 3.9
Lower boom and
measure time taken
from point where
bucket contacts
ground to point where
chassis rises from
ground

See Fig. O
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Arm horizontal and retract 0 Max. 1
bucket cylinder fully.
Then extend cylinder
and measure time
taken for arm to stop
Work equipment

at bottom and then

start again
Time lag Sec.
See Fig. P
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Bucket horizontal and retract 0 Max. 1
arm cylinder fully.
Then extend cylinder
and measure time
taken for bucket to
stop at bottom and
then start again

See Fig. Q
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Raise blade to max.
height. Then lower
Blade boom and measure Max. 1 Max. 2
time taken from point
where blade contacts
ground to point where
chassis rises from
ground

• Hydraulic oil tem-

Each cylinders perature: 45 – 55°C Max. 2 10
cc/
Internal leakage • Engine at full throttle mm
Center swivel • Relieve circuit to be
joint measured — —

PC27 – 45MRX-1 20-25

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC40MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

See Fig. N

• Engine at low idling

• Hydraulic oil tempera-
ture: 45 – 55°C
• Retract arm, boom
cylinders fully and set
Boom boom at max. height. Max. 2 Max. 3.9
Lower boom and
measure time taken
from point where
bucket contacts
ground to point where
chassis rises from
ground

See Fig. O

• Engine at low idling

• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Arm horizontal and retract 0 Max. 1
bucket cylinder fully.
Then extend cylinder
and measure time
taken for arm to stop
Work equipment

at bottom and then

start again
Time lag Sec.
See Fig. P
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Bucket horizontal and retract 0 Max. 1
arm cylinder fully.
Then extend cylinder
and measure time
taken for bucket to
stop at bottom and
then start again

See Fig. Q
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Raise blade to max.
height. Then lower
Blade boom and measure Max. 1 Max. 2
time taken from point
where blade contacts
ground to point where
chassis rises from
ground

• Hydraulic oil tem-

Each cylinders perature: 45 – 55°C Max. 2 10
cc/
Internal leakage • Engine at full throttle mm
Center swivel • Relieve circuit to be
joint measured — —

PC27 – 45MRX-1 20-31

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC45 MRX-1

Cat-
Item Measurement conditions Unit Standard value Service limit
egory for new machine value

See Fig. N

• Engine at low idling

• Hydraulic oil tempera-
ture: 45 – 55°C
• Retract arm, boom
cylinders fully and set
Boom boom at max. height. Max. 2 Max. 3.9
Lower boom and
measure time taken
from point where
bucket contacts
ground to point where
chassis rises from
ground

See Fig. O

• Engine at low idling

• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Arm horizontal and retract 0 Max. 1
bucket cylinder fully.
Then extend cylinder
and measure time
taken for arm to stop
Work equipment

at bottom and then

start again
Time lag Sec.
See Fig. P
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Set top of boom
Bucket horizontal and retract 0 Max. 1
arm cylinder fully.
Then extend cylinder
and measure time
taken for bucket to
stop at bottom and
then start again

See Fig. Q
• Engine at low idling
• Hydraulic oil tempera-
ture: 45 – 55°C
• Raise blade to max.
height. Then lower
Blade boom and measure Max. 1 Max. 2
time taken from point
where blade contacts
ground to point where
chassis rises from
ground

• Hydraulic oil tempera-

Each cylinders ture: 45 – 55°C Max. 2 10
cc/
Internal leakage • Engine at full throttle mm
Center swivel • Relieve circuit to be
joint measured — —

PC27 – 45MRX-1 20-37

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

fl Sketches related to Standard Value Table

PC27 – 45MRX-1 20-39

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

20-40 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

PC27 – 45MRX-1 20-41

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

20-42 PC27 – 45MRX-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

PC27 – 45MRX-1 20-43

 TESTING AND ADJUSTING

Tools for testing, adjusting, and troubleshooting ............................................................................... 20- 102

Measuring engine speed ....................................................................................................................... 20- 103
Measuring exhaust color ....................................................................................................................... 20- 104
Adjusting valve clearance ...................................................................................................................... 20- 105
Measuring compression pressure ........................................................................................................ 20- 106
Measuring engine oil pressure ............................................................................................................. 20- 108
Testing and adjusting fuel injection timing .......................................................................................... 20- 109
Testing and adjusting fan belt tension ................................................................................................. 20- 110
Adjusting fuel control lever ................................................................................................................... 20- 112
Measuring sprocket wear ...................................................................................................................... 20- 114
Testing and adjusting track shoe tension ............................................................................................... 20- 115
Hydraulic equipment adjusting control levers and pedal .................................................................. 20- 116
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ........................ 20- 119
Testing and adjusting LS differential pressure .................................................................................... 20- 127
Adjusting PC valve ................................................................................................................................. 20- 131
Testing control circuit pressure ............................................................................................................. 20- 132
Testing and adjusting control circuit pressure ..................................................................................... 20- 134
Measuring output pressure of solenoid valve ..................................................................................... 20- 136
Measuring output pressure of PPC valve ............................................................................................. 20- 139
Adjusting work equipment, swing PPC valve ...................................................................................... 20- 141
Testing swing holding brake inlet port presure ................................................................................... 20- 142
Testing and adjusting travel deviation ................................................................................................. 20- 146
Measuring oil leakage inside work equipment cylinder ..................................................................... 20- 148
Bleeding air ............................................................................................................................................. 20- 150
Releasing remaining pressure from hydraulic circuit ......................................................................... 20- 152
Releasing remaining pressure from hydraulic tank ............................................................................ 20- 152
Pressurizing hydraulic tank ................................................................................................................... 20- 152
Testing and adjusting hydraulic breaker sevice valve ......................................................................... 20- 153
Testing and charging pressure of hydraulic breaker gas (N2) ............................................................ 20- 154
Electrical related parts procedure for checking diode ........................................................................ 20- 157

PC27 – 45MRX-1 20-101

TESTING AND ADJUSTING MEASURING ENGINE SPEED

MEASURING ENGINE SPEED

¤ Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
fl Measure the engine speed under the following
conditions.
• Cooling water temperature: Within operating
range
• Hydraulic oil temperature : 45 – 55°C

1. Install clamp set A2 of multi-tachometer to fuel

injection tube (1), then connect to multi-tachom-
eter A1.

2. Start the engine, and measure the engine speed

when it is set to the conditions for measuring.
1) Measuring low idling and high idling speed:
Measure the engine speed with the fuel con-
trol lever set to low idling and high idling.
2) Measuring speed at 1-pump relief:
Run the engine at full throttle, operate the
bucket control lever, and measure the engine
speed when the bucket CURL is relieved.
3) Measuring speed at 2-pump relief:
Run the engine at full throttle, operate the
bucket and swing control levers, and measure
the engine speed when the bucket CURL and
swing are relieved.
¤ For the swing, use the work equipment
and lock securely.

PC27 – 45MRX-1 20-103

TESTING AND ADJUSTING MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR

• When measuring in the field where there is no air
or electric power supply, use Handy Smoke
Checker F1; when recording formal data, use
Smoke Meter F2.
fl Raise the coolant temperature to the operating
range before measuring.
¤ Be careful not to touch any hot parts when re-
moving or installing the measuring tools.

1. Measuring with Handy Smoke Checker F1.

1) Install filter paper to Handy Smoke Checker
F1.
2) Insert the exhaust gas suction port into the
exhaust pipe.
3) Accelerate the engine suddenly, and operate
the handle of Handy Smoke Checker F1 at the
same time to collect the exhaust gas on the
filter paper.
4) Remove the filter paper and compare it with
the scale supplied to judge the condition.

2. Measuring with Smoke Meter F2

1) Insert the probe of Smoke Meter F2 into the
outlet port of the exhaust pipe, and tighten
the clip to secure it to the exhaust pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to Smoke
Meter F2.
fl Keep the pressure of the air supply below
15 kg/cm2.
3) Connect the power cord to the AC100V socket.
fl When connecting the cord, check that the
power switch of the smoke meter is OFF.
4) Loosen the cap nut of the suction pump, and
fit the filter paper.
fl Fit the filter paper securely so that the ex-
haust gas cannot leak.
5) Turn the power switch of Smoke Meter F2 ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of Smoke Meter F2 at
the same time to collect the exhaust gas color
on the filter.
7) Place the filter paper used to catch the exhaust
gas color on top of at least 10 sheets of un-
used filter paper inside the filter paper holder,
and read the value shown.

20-104 PC27 – 45MRX-1

TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE
CLEARANCE
1. Remove air cleaner (1), then remove the cylinder
head cover.

2. Remove cap (2) of the flywheel housing.

3. Rotate the crankshaft in the normal direction to

align the No. 1 line b on the flywheel with line a
on the housing. When rotating, check the move-
ment of the valves of the No. 1 cylinder (flywheel
end).
fl Using a mirror, look at lines a and b.
If a crane is available, remove the counter-
weight. This makes it easier to see.
fl Cylinder No. 1 is the cylinder at the flywheel
end of the engine.
fl When the crankshaft is rotated, the valves of
the cylinder at top dead center do not move.
If the valves are moving, rotate the crankshaft
one more turn and align the lines.
fl PC30MRX, PC35MRX: Rotate the crankshaft
240° each time and adjust the valve clear-
ance of each cylinder according to the firing
order.
• Firing order : 1—3—2
fl PC40MRX, PC45MRX: Rotate the crankshaft
180° each time and adjust the valve clearance
of each cylinder according to the firing order.
• Firing order : 1—3—4—2
fl There is a line on the flywheel for the top dead
center of each cylinder.

4. To adjust the valve clearance, loosen locknut (6),

then insert feeler gauge E between rocker lever
(3) and valve stem (4), and turn adjustment screw
(5) until the clearance is a sliding fit. Then tighten
locknut (6) to hold the adjustment screw in posi-
tion.
9 Locknut : 25.48 ± 2.94 Nm {2.6 ± 0.3 kgm}
fl After tightening the locknut, check the clear-
ance again.

PC27 – 45MRX-1 20-105

TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION
PRESSURE
MACHINE MODEL: PC27MRX
¤ When measuring the compression pressure, be
careful not to touch the exhaust manifold or muf-
fler, or to get your clothes caught in the fan, fan
belt or other rotating parts.

1. Adjust the valve clearance.

For details, see ADJUSTING VALVE CLEARANCE.

2. Warm up the engine to make the oil temperature

40 – 60°C.

3. Remove nozzle holder assembly (1) from the cyl-

inder to be measured.

4. Install adapter D2 and joint D3 to the mount of

the nozzle holder, then connect compression
gauge D1.
9 Adapter mounting nut:
4.41 ± 0.49 Nm {0.45 ± 0.05 kgm}

5. Disconnect engine stop solenoid connector (1).

6. Close the fuel filter stop valve.

7. Crank the engine with the starting motor and mea-

sure the compression pressure.
fl Measure the compression pressure at the
point where the compression gauge indica-
tor remains steady.
fl When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.

fl After measuring the compression pressure, install

the nozzle holder assembly.
9 Nozzle holder mounting nut:
4.41 ± 0.49 Nm {0.45 ± 0.05 kgm}

20-106 PC27 – 45MRX-1

TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

MACHINE MODEL: PC30, 35, 40, 45MRX

¤ When measuring the compression pressure, be
careful not to touch the exhaust manifold or muf-
fler, or to get your clothes caught in the fan, fan
belt or other rotating parts.

1. Adjust the valve clearance.

For details, see ADJUSTING VALVE CLEARANCE.

2. Warm up the engine to make the oil temperature

40 – 60°C.

3. Remove nozzle holder assembly (1) from the cyl-

inder to be measured.

4. Install adapter D2 and joint D3 to the mount of

the nozzle holder, then connect compression
gauge D1.
9 Adapter mounting nut:
4.41 ± 0.49 Nm {0.45 ± 0.05 kgm}

5. Disconnect engine stop solenoid connector (2).

6. Close the fuel filter stop valve.

7. Crank the engine with the starting motor and mea-

sure the compression pressure.
fl Measure the compression pressure at the
point where the compression gauge indica-
tor remains steady.
fl When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.

fl After measuring the compression pressure, install

the nozzle holder assembly.
9 Nozzle holder mounting nut:
4.41 ± 0.49 Nm {0.45 ± 0.05 kgm}

PC27 – 45MRX-1 20-107

TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL

PRESSURE
fl Measure the engine oil pressure under the fol-
lowing conditions.
• Cooling water temperature: Within operating
range

1. Remove engine oil pressure switch (1).

2. Install nipple C2, then connect oil pressure gauge

C4 (1.0 MPa {10 kg/cm2}).

3. Start the engine, and measure the oil pressure

with the engine at low idling and high idling.

20-108 PC27 – 45MRX-1

TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING

FUEL INJECTION TIMING
Testing
fl If the fuel injection pump has been removed and
installed, check as follows.

1. Check that line a on the fuel injection pump is

aligned with line b on the flange.
fl The line on the flange is the 6th line from the
top.

Adjusting
fl If the lines are not aligned, adjust as follows.

1. Loosen mounting nut (1), then move fuel injec-

tion pump (2) to align the line.

2. Tighten nut (1).

9 Fuel injection pump mounting nut:
25.48 Nm {2.6 kgm}

PC27 – 45MRX-1 20-109

TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN

BELT TENSION
Testing
• Check that the deflection of the fan belt is 10 – 15
mm when pressed with a force of approx. 5.9 MPa
{approx. 6 kg} at a point midway between the al-
ternator and the fan pulley.

Adjusting
MACHINE MODEL: PC27, 30MRX

fl If the deflection is not correct, adjust as follows.

1. Remove the alternator side cover.

2. Loosen belt tension adjustment nut (1) and alter-

nator mounting nut (2).

3. Using bar 1, move alternator (3) towards the front

of the chassis, then tighten belt tension adjust-
ment bolt (1).

4. Tighten alternator mounting nut (2).

MACHINE MODEL: PC35MRX

fl If the deflection is not correct, adjust as follows.

1. Remove right lever stand (1) together with the

mounting bracket.

2. Loosen the alternator mounting nut and adjust-

ment bolt (2).

3. Using bar 1, move alternator (3) towards the front

of the chassis, then tighten belt tension adjust-
ment bolt (2).

4. Tighten the alternator mounting nut.

20-110 PC27 – 45MRX-1

TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION

MACHINE MODEL: PC40, 45MRX

fl If the deflection is not correct, adjust as follows.

1. Remove cover (1) on the inside of the hydraulic

tank.

2. Remove cover (2) on the outside of the alternator.

3. Loosen alternator mounting bolt (3) and adjust-

ment bolt (4).

4. Using bar 1, move alternator (5) towards the front

of the chassis, then tighten belt tension adjust-
ment bolt (3).

5. Tighten alternator mounting nut (4).

PC27 – 45MRX-1 20-111

TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LEVER

ADJUSTING FUEL CONTROL

LEVER
MACHINE MODEL: PC27, 30MRX

1. Set fuel control lever (1) to the idling position and

fix stopper bolt (2) to the standard dimension
• Standard dimension of stopper bolt (2): 13
mm
fl When doing this, check that fuel injection
pump lever (3) is in contact with IDLING stop-
per (4).

2. Move the fuel control lever towards the FULL

position and fix stopper bolt (6) in position at the
point where the fuel injection pump lever con-
tacts FULL stopper (5).

3. Check that the fuel control lever moves smoothly.

4. Stop the engine and check the engine speed.

fl For details of the engine speed, see STAN-
DARD VALUES FOR ENGINE RELATED PARTS.

20-112 PC27 – 45MRX-1

TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LEVER

MACHINE MODEL: PC35, 40, 45MRX

1. Adjust LOW IDLING stopper bolt (1) to dimension

a, then tighten the locknut.
• Mounting dimension a: 6.9 mm
fl Loosen the HIGH IDLING stopper bolt.

2. Set fuel control lever (2) to the LOW IDLING posi-

tion.

3. Adjust the yoke portion at the fuel control lever

end of cable (3) to dimension b, then tighten the
locknut.
• Mounting dimension b: 92.9 mm

4. Set fuel control lever (3) to the HIGH IDLING posi-

tion.

5. Adjust the yoke at the fuel injection pump end of

cable (3) so that lever (4) of the fuel injection pump
contacts stopper bolt (5), then tighten the lock-
nut.
• Mounting dimension c (reference): 109 mm
1) Adjust HIGH IDLING stopper bolt (6) so that it
contacts the fuel control lever (2), then tighten
the locknut.
• Mounting dimension d: 11.9 mm

PC27 – 45MRX-1 20-113

TESTING AND ADJUSTING MEASURING SPROCKET WEAR

MEASURING SPROCKET WEAR

1. Remove the track shoe assembly.

fl For details, see DISASSEMBLY AND ASSEM-
BLY, REMOVAL OF RUBBER SHOE ASSEM-
BLY or REMOVAL OF STEEL SHOE ASSEM-
BLY.

2. Align wear gauge M with the sprocket.

fl Align the standard line, then align the wave
shape of the sprocket with the wave shape of
the wear gauge.

3. Judge the sprocket wear.

fl If the wave shape of the sprocket is above the
wear limit line: It is possible to continue to
use the sprocket.
fl If the wave shape of the sprocket has reached
the wear limit line: Replace the sprocket with
a new part.

20-114 PC27 – 45MRX-1

 HYDRAULIC EQUIPMENT
TESTING AND ADJUSTING ADJUSTING CONTROL LEVERS AND PEDAL

HYDRAULIC EQUIPMENT
ADJUSTING CONTROL LEVERS
AND PEDAL
1. Adjusting blade control lever
1) Adjust front and rear stopper bolts (7) and (8)
to dimension e, set blade control lever (9) at
the HOLD position, then tighten the locknut
temporarily.
• Temporary mounting dimension e:
6.9 mm (PC35MRX)
7.0 mm (PC40, 45MRX)
2) Adjust the yoke at the lever end of cables (10)
and (11) to dimension f.
• Mounting dimension f: 106.7 mm
3) Adjust the yoke at the valve end of cables (10)
and (11) to dimensions g (g1, g2).
• Mounting dimension:
g1: 113 mm (PC35MRX)
g2: 105.5 mm (PC35MRX)
Mounting dimension:
g: 104 mm (PC40, 45MRX)
4) Loosen stopper bolts (7) and (8), and retract
fully.
5) Operate blade control lever (9) fully to the
front and rear, adjust so that stopper bolts (7)
and (8) are in contact at their respective posi-
tions, then tighten the locknut.

20-116 PC27 – 45MRX-1

 HYDRAULIC EQUIPMENT
TESTING AND ADJUSTING ADJUSTING CONTROL LEVERS AND PEDAL

2) Adjust the yoke at the lever end of cables (20)

and (21) to dimension n.
fl Cable (20) is on the PC35MRX only.
• Mounting dimension n:
125 mm (PC35MRX)
111 mm (PC40, 45MRX)
3) Adjust the yoke at the valve end of cables (20)
and (21) to dimension p.
• Mounting dimension p:
125 mm (PC35MRX)
101.8 mm (PC40, 45MRX)
4) Loosen stopper bolts (17) and (18), and retract
fully.
5) Operate boom swing control pedal (19) fully
to the front and rear, adjust so that stopper
bolts (17) and (18) are in contact at their re-
spective positions, then tighten the locknut.

20-118 PC27 – 45MRX-1

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

TESTING AND ADJUSTING

HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING,
TRAVEL CIRCUIT
MACHINE MODEL: PC27, 30MRX
Measuring
fl Oil temperature when measuring: 45 – 55°C
¤ Lower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK posi-
tion.

1. Remove the pressure pick-up plug (Thread PT1/

8) from the circuit to be measured, then install
nipple C2 and oil pressure gauge C1 (39.2 MPa
{400 kg/cm2}).

2. Start the engine and measure the main relief pres-

sure with the engine at full throttle.
• Condition of actuator to be measured
1) For the work equipment, set each cylinder to
the end of its stroke.
2) For the swing, dig a hole and lower the bucket.
3) For the travel, fit block 1 under the track shoe
grouser, or fit block 2 between the sprocket
and frame to lock the track shoe. Measure
one side at a time.
fl The set pressure of the swing motor safety
valve is lower than the set pressure of the
main relief valve, so if the swing is re-
lieved, the pressure is the set pressure of
the safety valve.

PC27 – 45MRX-1 20-119

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

Adjusting
fl For the swing circuit, adjust the swing motor
safety valve. For the work equipment and travel
circuits, adjust the main relief valve.

1. Main relief valve (1)

• Boom, bucket: For R.H. travel
• Arm: For L.H. travel
• Blade, offset: For swing
1) Loosen locknut (2) and turn adjustment screw
(3) to adjust.
fl Turn the adjustment screw to adjust as fol-
lows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
2) After adjusting, tighten locknut (2).
9 Locknut : 68.6 ± 9.8 Nm {7 ± 1 kgm}
fl After adjusting, use the measurement pro-
cedure above to check again.

2. Swing motor safety valve (4)

fl If the swing relief pressure is not correct, ad-
just the swing motor safety valve as follows.
1) Loosen locknut (5) and turn adjustment screw
(6) to adjust.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
2) After adjusting, tighten locknut (5).
9 Locknut :
90.65 ± 12.25 Nm {9.25 ± 1.25 kgm}
fl After adjusting, use the measurement pro-
cedure above to check again.

20-120 PC27 – 45MRX-1

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

3. Measuring swing relief pressure

1) Remove oil pressure measurement plug (2)
(PT 1/8).

2) Fit nipple C2, then install oil pressure gauge

C1 (39.2 MPa {400 kg/cm2}).
3) Run the engine at full throttle and measure
the oil pressure when the swing is relieved.
¤ Use the work equipment to lock the swing
securely.

20-122 PC27 – 45MRX-1

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

Adjusting
fl The unload valve cannot be adjusted.

1. Adjusting main relief valve

fl If the work equipment and travel relief pres-
sure is not normal, adjust the main relief valve
as follows.
1) Main relief valve (3) of loosen locknut (4) and
turn adjustment screw (5) to adjust.
fl Turn the adjustment screw to adjust as fol-
lows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
fl Amount of adjustment for one turn of ad-
justment screw: 19.6 MPa {200 kg/cm2}
2) After adjusting, tighten locknut (4).
9 Locknut: 39 ± 49 Nm {4 ± 5 kgm}
fl After completion of adjustment, repeat the
measurement procedure above to check the
oil pressure again.

2. Swing motor safety valve

fl If the swing relief pressure is not normal, ad-
just the swing motor safety valve (6) as fol-
lows.
1) Loosen locknut (7) and turn adjustment screw
(8) to adjust.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
fl Amount of adjustment for one turn of ad-
justment screw: 17.54 MPa {179 kg/cm2}
2) After adjusting, tighten locknut (5).
9 Locknut:
78.4 ± 102.9 Nm {8 ± 10.5 kgm}
fl After completion of adjustment, repeat the
measurement procedure above to check the
oil pressure again.

PC27 – 45MRX-1 20-123

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

MACHINE MODEL: PC40, 45MRX

Measuring
fl Oil temperature when measuring: 45 – 55°C
¤ Before removing the hydraulic pressure mea-
surement plug, release the remaining pressure
in the hydraulic tank. For details, see RELEAS-
ING AIR FROM HYDRAULIC TANK.
¤ After installing the oil pressure gauge, pressur-
ize the hydraulic tank. For details, see PRES-
SURIZING HYDRAULIC TANK.

1. Measuring unload pressure

1) Remove oil pressure measurement plug (1)
(Thread dia.= 10mm, pitch= 1.25 mm).
2) Install nipple C2, then install oil pressure
gauge C1 (39.2 MPa {400 kg/cm2}).
3) Run the engine at full throttle and measure
the oil pressure when all control levers are at
HOLD.

2. Measuring work equipment, travel relief pressure

1) Remove oil pressure measurement plug (1).
2) Install nipple C2, then install oil pressure
gauge C1 (39.2 MPa {400 kg/cm2}).
3) Run the engine at full throttle and measure
the oil pressure when each actuator is re-
lieved.
¤ Operate each work equipment cylinder to the
end of its stroke.
¤ For the travel, fit block 1 under the track
shoe grouser, or fit block 2 between the
sprocket and frame to lock the track shoe.

20-124 PC27 – 45MRX-1

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

3. Measuring swing relief pressure

1) Remove oil pressure measurement plug (2)
(PT 1/8).

2) Fit nipple C2, then install oil pressure gauge

C1 (39.2 MPa {400 kg/cm2}).
3) Run the engine at full throttle and measure
the oil pressure when the swing is relieved.
¤ Use the work equipment to lock the swing
securely.

PC27 – 45MRX-1 20-125

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

Adjusting
fl The unload valve cannot be adjusted.

1. Adjusting main relief valve

fl If the work equipment and travel relief pres-
sure is not normal, adjust the main relief valve
as follows.
1) Loosen locknut (4) for main relief valve (3) and
turn adjustment screw (5) to adjust.
fl Turn the adjustment screw to adjust as fol-
lows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
fl Amount of adjustment for one turn of ad-
justment screw: 19.6 MPa {200 kg/cm2}
2) After adjusting, tighten locknut (4).
9 Locknut: 39 ± 49 Nm {4 ± 5 kgm}
fl After completion of adjustment, repeat the
measurement procedure above to check the
oil pressure again.

2. Swing motor safety valve

fl If the swing relief pressure is not normal, ad-
just the swing motor safety valve (6) as fol-
lows.
1) Loosen locknut (7) and turn adjustment screw
(8) to adjust.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
fl Amount of adjustment for one turn of ad-
justment screw: 17.54 MPa {179 kg/cm2}
2) After adjusting, tighten locknut (8).
9 Locknut:
78.4 ± 102.9 Nm {8 ± 10.5 kgm}
fl After completion of adjustment, repeat the
measurement procedure above to check the
oil pressure again.

20-126 PC27 – 45MRX-1

TESTING AND ADJUSTING TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE

TESTING AND ADJUSTING LS

DIFFERENTIAL PRESSURE
Measuring
MACHINE MODEL: PC27, 30MRX
1. Measuring with differential pressure gauge
1) Remove oil pressure measurement plugs (1)
and (2) (Thread dia.=10mm, Pitch=1.25mm).
2) Fit nipple C2, then install differential pressure
gauge C5.
fl Connect pump discharge pressure (1) to
the high-pressure side of the differential
pressure gauge and LS pressure (2) to the
low-pressure side.
3) Using the work equipment, push up the track
on one side.
4) Run the engine at full throttle, set to the con-
ditions in the table, and measure the LS dif-
ferential pressure.
• LS differential when the travel pressure
lever is at neutral: 4.41 ± 0.49 {45 ± 5 kg/
cm2}
fl The LS differential pressure when the
travel lever is at neutral is the same as
the unload pressure.
• LS differential pressure when travel lever
is partially operated (free rotation of
travel): 1.57 ± 0.1 MPa {16 ± 1 kg/cm2}

2. Measuring with oil pressure gauge

fl The differential pressure at its maximum is
less than 1.96 MPa {20 kg/cm2}, so measure
with the same pressure gauge.
1) Remove oil pressure measurement plugs (1)
and (2) (Thread dia.=10mm, Pitch=1.25mm).
2) Fit nipple C2, then install oil pressure gauge
C1 (39.2 MPa {400 kg/cm2}).
fl Use a gauge with a scale in units of 9.8
MPa {10 kg/cm2}.
3) Using the work equipment, push up the track
on one side.
4) Run the engine at full throttle, set to the con-
ditions in the table, and measure the pump
discharge pressure.
fl Read the gauge indicator accurately from
directly in front of it.
5) Run the engine at full throttle, set to the con-
ditions in the table, and measure the LS pres-
sure.
fl Read the gauge indicator accurately from
directly in front of it.
6) Calculate the LS differential pressure from the
pump discharge pressure and the LS pres-
sure.

PC27 – 45MRX-1 20-127

TESTING AND ADJUSTING TESTING CONTROL CIRCUIT PRESSURE

TESTING CONTROL CIRCUIT

PRESSURE
MACHINE MODEL.: PC27, 30MRX
Measuring
fl Oil temperature when measuring: 45 – 55°C
¤ Lower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK posi-
tion.
1. Disconnect hose (1) going to the solenoid valve
and install oil pressure gauge C1 (5.9 MPa {60 kg/
cm2}).

2. Start the engine and measure with the engine at

full throttle.
fl When testing for internal leakage of the equip-
ment in the control circuit, use the parts given
below to shut off the circuit for the following
sections when measuring the relief pressure.

Use the following parts to shut off the circuit.

• Sleeve nut for elbow: 07221-20210
Plug: 07222-00210
• Plug for hose: 07376-50210

Section of hydraulic Component that can be

No. circuit shut off checked

Control relief valve

PPC lock solenoid valve
1 outlet part PPC lock solenoid valve

2 Left PPC valve inlet part Left PPC valve

3 Right PPC valve inlet port Right PPC valve

4 Solenoid valve inlet port Solenoid valve block

Travel boost solenoid Travel motor, travel

5 outlet port boost solenoid valve

Solenoid, EPC valve inlet Solenoid, EPC valve

6 port block

20-132 PC27 – 45MRX-1

3
TESTING AND ADJUSTING TESTING CONTROL CIRCUIT PRESSURE

Adjusting
1. Loosen locknut (2) and turn adjustment screw (3)
to adjust.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTER-
CLOCKWISE
2. After adjusting, tighten locknut (2).
9 Locknut : 8.8 ± 10 Nm {0.9 ± 0.1 kgm}

fl After adjusting, use the measurement proce-

dure above to check again.

PC27 – 45MRX-1 20-133

TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE

TESTING AND ADJUSTING

CONTROL CIRCUIT PRESSURE
MACHINE MODEL: PC35MRX
Measuring
fl Oil temperature when measuring: 45 – 55°C

1. Remove oil pressure measurement plug (1) of the

solenoid valve assembly.

2. Fit nipple C2, then install oil pressure gauge C1

(5.9 MPa {60 kg/cm2}).

3. Run the engine at full throttle and measure the

oil pressure when the control levers are at neu-
tral.

Adjusting
fl If the control circuit pressure is not correct, ad-
just the control relief valve as follows.

1. Loosen locknut (2) and turn adjustment screw (3)

to adjust.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTER-
CLOCKWISE
fl Amount of adjustment for one turn of adjust-
ment screw: 343 kPa {3.5 kg/cm2}

2. After adjusting, tighten locknut (2).

fl After adjusting, use the measurement proce-
dure above to check again.
9 Locknut : 9.8 Nm {1.0 kgm}

fl After adjusting, use the measurement proce-

dure above to check the oil pressure again.

20-134 PC27 – 45MRX-1

TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE

MACHINE MODEL: PC40, 45MRX

Measuring
fl Oil temperature when measuring: 45 – 55°C

1. Remove oil pressure measurement plug (1).

2. Fit nipple C2, then install oil pressure gauge C1

(5.9 MPa {60 kg/cm2}).

3. Run the engine at full throttle and measure the

oil pressure when the control levers are at neu-
tral.

Adjusting
fl If the control circuit pressure is not correct, ad-
just the control relief valve as follows.

1. Loosen locknut (2) and turn adjustment screw (3)

to adjust.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTER-
CLOCKWISE
fl Amount of adjustment for one turn of adjust-
ment screw: 343 kPa {3.5 kg/cm2}

2. After adjusting, tighten locknut (2).

fl After adjusting, use the measurement proce-
dure above to check again.
9 Locknut : 9.8 Nm {1.0 kgm}

fl After adjusting, use the measurement proce-

dure above to check the oil pressure again.

PC27 – 45MRX-1 20-135

TESTING AND ADJUSTING MEASURING OUTPUT PRESSURE OF SOLENOID VALVE

MEASURING OUTPUT
PRESSURE OF SOLENOID
VALVE
MACHINE MODEL: PC27, 30MRX
fl Oil temperature when measuring: 45 – 55°C
• Measure the solenoid valves at the locations be-
low.

No. Solenoid valve Measurement location

1 PPC lock Solenoid valve outlet port

2 Travel boost stop Solenoid valve outlet port

1. Remove the outlet hose from the control valve to

be measured, then connect adapter C3 between
the hose and the fixed portion.

2. Install oil pressure gauge C1 (5.9 MPa {60 kg/cm2})

to adapter C3.

3. Run the engine at full throttle and measure the

output pressure under the following conditions.
1) PPC lock solenoid valve
• Make the safety lock valve free.
2) Travel boost solenoid valve
• Depress the travel boost pedal.

20-136 PC27 – 45MRX-1

TESTING AND ADJUSTING MEASURING OUTPUT PRESSURE OF SOLENOID VALVE

MACHINE MODEL: PC35, 40, 45MRX

fl Oil temperature when measuring: 45 – 55°C

1. Disconnect outlet hose (1) or (2) of the solenoid

valve to be measured.
• (1): PPC lock solenoid valve
• (2): Travel boost solenoid valve

2. Fit adapter C3 and nipple C2, then install oil pres-

sure gauge C1 (5.9 MPa {60 kg/cm2}).

PC27 – 45MRX-1 20-137

TESTING AND ADJUSTING MEASURING OUTPUT PRESSURE OF SOLENOID VALVE

3. Run the engine at full throttle and measure the

output pressure under the conditions in the table
below.

Solenoid Measurement Condition Oil pressure

No. valve conditions of solenoid (MPa {kg/cm2})

Lock lever at 0
LOCK OFF {0}
1 PPC
lock Lock lever at 2.94 +0.49
–0.1
FREE ON {30 +5
–1 }

Boost pedal 0
OFF OFF {0}
2 Travel
boost Boost pedal 2.94 +0.49
–0.1
ON ON {30 +5
–1 }

20-138 PC27 – 45MRX-1

TESTING AND ADJUSTING MEASURING OUTPUT PRESSURE OF PPC VALVE

MEASURING OUTPUT
PRESSURE OF PPC VALVE
MACHINE MODEL: PC27, 30MRX
fl Carry out this operation if the speed of the work
equipment or swing is too slow or it does not
move.
fl Oil temperature when measuring: 45 – 55°C

1. Remove the outlet hose from the PPC valve to be

measured. Connect adapter C3 between the hose
and the elbow, then install oil pressure gauge C1
(5.9 MPa {60 kg/cm2}) to adapter C3.

2. Run the engine at full throttle, operate the con-

trol lever for the circuit to be measured, and mea-
sure the output pressure of the PPC valve.
• Position for measurement
1) Left PPC valve
• Arm IN/OUT
• Left, right swing
2) Right PPC valve
• Boom RAISE, LOWER
• Bucket DUMP, CURL

MACHINE MODEL: PC35, 40, 45MRX

fl Oil temperature when measuring: 45 – 55°C

1. Disconnect PPC hose (1) of the circuit to be mea-

sured.
fl For details of the hose to disconnect, see
TESTING SWING HOLDING BRAKE INLET
PORT PRESSURE.

PC27 – 45MRX-1 20-139

TESTING AND ADJUSTING MEASURING OUTPUT PRESSURE OF PPC VALVE

2. Fit adapter C3 and nipple C2, then install oil pres-

sure gauge C1 (5.9 MPa {60 kg/cm2}).

3. Run the engine at full throttle, operate the con-

trol lever, and measure the output pressure.
fl The standard value is the same as the control
circuit pressure (when the control lever is
operated fully).

20-140 PC27 – 45MRX-1

TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT, SWING PPC VALVE

ADJUSTING WORK EQUIPMENT,

SWING PPC VALVE
fl If there is excessive play in the work equipment
or swing lever, adjust as follows.
¤ Lower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK posi-
tion.

1. Remove the PPC valve.

fl For details, see DISASSEMBLY AND ASSEM-
BLY, REMOVAL OF PPC VALVE ASSEMBLY.

2. Remove boot (1).

3. Loosen locknut (2), then screw in disc (3) to a po-

sition where it contacts the heads of 4 pistons (4).
fl When doing this, do not make the piston
move.

4. Fix the position of disc (3), then tighten locknut

(2) to the specified torque.
9 Locknut : 107.9± 9.8Nm {11 ± 1 kgm}

5. Install boot (1).

fl With the above adjustment, the clearance be-

tween disc (3) and piston (4) becomes 0.

PC27 – 45MRX-1 20-141

TESTING AND ADJUSTING TESTING SWING HOLDING BRAKE INLET PORT PRESSURE

TESTING SWING HOLDING

BRAKE INLET PORT PRESSURE
fl Oil temperature when measuring: 45 – 55°C

MACHINE MODEL: PC27, 30MRX

1. Disconnect hose (1).

2. Fit adapter C3 and nipple C2, then install oil pres-

sure gauge C1 (5.9 MPa {60 kg/cm2}).

3. Measure the inlet port pressure with the engine

at full throttle and the control lever operated to
left swing or right swing.
fl The standard value is the same as the control
circuit pressure (when the control lever is
operated fully).

20-142 PC27 – 45MRX-1

TESTING AND ADJUSTING TESTING SWING HOLDING BRAKE INLET PORT PRESSURE

MACHINE MODEL: PC35MRX

1. Disconnect hose (2) from the swing motor.

2. Fit adapter C3 and hose 1 to hose (2).

fl Fit a blind plug to the female end of adapter
C3.
• Hose 1 part No.: 22F-62-11440

3. Fit nipple C2, then install oil pressure gauge C1

(5.9 MPa {60 kg/cm2}).

4. Measure the inlet port pressure with the engine

at full throttle and the control lever operated to
left swing, right swing, or arm IN.
fl The standard value is the same as the control
circuit pressure (when the control lever is
operated fully).

PC27 – 45MRX-1 20-143

TESTING AND ADJUSTING TESTING SWING HOLDING BRAKE INLET PORT PRESSURE

MACHINE MODEL: PC40, 45MRX

1. Disconnect hose (3) from the main control valve.

2. Fit adapter C3 and nipple C2, then install oil pres-

sure gauge C1 (5.9 MPa {60 kg/cm2}).

3. Measure the inlet port pressure with the engine

at full throttle and the control lever operated to
left swing or right swing.
fl The standard value is the same as the control
circuit pressure (when the control lever is
operated fully).

20-144 PC27 – 45MRX-1

TESTING AND ADJUSTING TESTING SWING HOLDING BRAKE INLET PORT PRESSURE

<Reference>
• If the PPC valve output pressure is normal for
all of left swing, right swing, and arm IN, and
the swing holding brake inlet port pressure is
not normal for any of these operations, it can
be judged that the PPC shuttle valve for the
abnormal system is defective.
• The PPC shuttle valve is assembled inside the
control valve spring case.

PC27 – 45MRX-1 20-145

TESTING AND ADJUSTING MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER

MEASURING OIL LEAKAGE

INSIDE WORK EQUIPMENT
CYLINDER
fl Oil temperature when measuring: 45 – 55°C
fl If the hydraulic drift of the work equipment ex-
ceeds the standard value, measure the leakage
inside the cylinder as follows to check if the cause
of the hydraulic drift is in the control valve or the
cylinder.
• If the leakage is within the standard value, the
control valve is the cause.
• If the leakage is not within the standard value,
the cylinder is the cause.

1. Fully extend the rod of the work equipment cylin-

der to be measured, then stop the engine.

2. Disconnect the hose at the head end and block

the hose at the chassis end with a blind plug.
• Boom cylinder: (1) hose
• Arm cylinder: (2) hose
• Bucket cylinder: (3) hose
¤ Be careful not to disconnect the piping at the
bottom end.

3. Start the engine, run at full throttle, and apply

relief pressure to the bottom end of the cylinder.
fl Boom cylinder: Operate to RAISE
Arm cylinder: Operate to IN
Bucket cylinder: Operate to CURL

4. Wait for 30 seconds, then measure the leakage

for the next one minute.

20-148 PC27 – 45MRX-1

TESTING AND ADJUSTING MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER

PC27 – 45MRX-1 20-149

 RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT,
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK,
TESTING AND ADJUSTING PRESSURIZING HYDRAULIC TANK

RELEASING REMAINING RELEASING REMAINING

PRESSURE FROM PRESSURE FROM
HYDRAULIC CIRCUIT HYDRAULIC TANK
¤ There is no accumulator installed, so the re- ¤ The hydraulic tank is a sealed type, so it is
maining pressure in the piping between the pressurized.
control valve and hydraulic cylinder or swing When removing the hoses or plugs installed
motor cannot be released by operating the to the hydraulic tank, release the remaining
control levers. pressure in the hydraulic tank as follows.
When the above piping is removed, be care-
ful of the following points. 1. Lower the work equipment to the ground and
stop the engine.
1. Run the engine at low idling, operate the hy-
draulic cylinders so that as far as possible the 2. Loosen the hydraulic tank oil filler plug slowly
pressure is not relieved at the end of the stroke, to release the pressure inside the hydraulic
lower the work equipment to the ground, then tank.
stop the engine.
fl If the engine is stopped with the hydraulic
circuit relieved and the hydraulic cylinder
at the end of its stroke, do not carry out
any work for 5 to 10 minutes.

2. When removing the piping, loosen the piping PRESSURIZING HYDRAULIC

sleeve nut gradually to release the pressure
remaining in the piping slowly, then remove
TANK
the piping after the oil stops spurting out. fl If the oil filler plug of the hydraulic tank has
been removed, pressurize the hydraulic tank
as follows.

1. Run the engine at low idling and set the work

equipment to the pressurizing posture.

2. Stop the engine, open the hydraulic tank oil

filler plug, then tighten it again.
9 Drain plug (PC35MRX):
181.3 – 240.1 Nm {18.5 – 24.5 kgm}
fl This operation pressurizes the hydraulic
tank.

3. Start the engine and lower the work equipment

to the ground.

20-152 PC27 – 45MRX-1

TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC BREAKER SERVICE VALVE

TESTING AND ADJUSTING

HYDRAULIC BREAKER SERVICE
VALVE
fl If the pressure or amount of oil flowing to the
hydraulic breaker is not within the specified range,
it will cause a drop in the impact speed or varia-
tion in the impact force.
If the impact breaking force drops or varies, carry
out adjustment as follows.

Measuring
fl Oil temperature when measuring: 45 – 55°C
¤ Lower the work equipment to the ground and
stop the engine. Then loosen the oil filler cap
slowly to release the pressure inside the hydrau-
lic tank.

1. Disconnect the hydraulic breaker piping and set

a flowmeter in position.

2. Start the engine and measure the oil pressure and

flow.

Adjusting
1. Adjust dimension A between stopper bolt (1) and
the bottom surface of control pedal (2).
• Standard dimension: 7.5 mm

2. After adjusting clearance A, refer to the graph

below and check that the oil pressure and flow is
within the specified range.
fl If it is not within the specified range, check
the main relief pressure of the control valve.
For details, see TESTING AND ADJUSTING
OF WORK EQUIPMENT, SWING, TRAVEL CIR-
CUIT.

PC27 – 45MRX-1 20-153

 TESTING AND CHARGING PRESSURE OF
TESTING AND ADJUSTING HYDRAULIC BREAKER GAS (N2)

TESTING AND CHARGING

PRESSURE OF HYDRAULIC
BREAKER GAS (N2)
Ambient temperature Charge pressure
(°C) (MPa {kg/cm2})
MACHINE MODEL: PC35, 40, 45MRX
fl If the gas pressure at the back head of the hy- -20 – -10 1.08 {11.0}
draulic breaker is not within the standard range, -10 – 1 1.13 {11.5}
the breaking force will go down. If it is felt that
the impact breaking force has dropped, check the 1 – -14 1.18 {12.0}
gas pressure and charge with gas as follows. 14 – 26 1.23 {12.5}

Precautions about gas pressure 26 – 36 1.27 {13.0}

fl The gas pressure varies according to the ambi- 36 – 50 1.32 {13.5}
ent temperature, so compensate the specified
charging pressure according to the ambient tem-
perature. (See the table on the right.)
• Specified charging pressure: 1.23 MPa {12.5 kg/
cm2} (ambient temperature: 20°C)
fl If the temperature of the hydraulic breaker is high,
the pressure will be displayed as higher than it
actually is, so measure when the temperature of
the hydraulic breaker is the same as the ambient
temperature.
fl When measuring the gas pressure, set with the
breaker perpendicular and the chisel raised from
the ground surface.
If the chisel is touching the ground, the pressure
will appear to be higher than it actually is.

Measuring gas pressure

1. Connect pressure gauge 1 (tool supplied with
machine) and check adapter 2 (tool supplied with
machine).

2. Remove the protective cap from charging valve

(1) of the hydraulic breaker.

3. Push check adapter 2 into the tip of charging

valve (1).
fl When the check adapter is pushed in, there is
danger that hydraulic oil may spray out from
the charging valve, so be careful not to put
your face close to the valve.

4. With check adapter 2 pushed in, measure the

reading of pressure gauge 1.

20-154 PC27 – 45MRX-1

 TESTING AND CHARGING PRESSURE OF
TESTING AND ADJUSTING HYDRAULIC BREAKER GAS (N2)

Action after measuring gas pressure

fl Even if the gas pressure is normal, hydraulic oil
collects in the back head gas chamber due to the
structure of the hydraulic breaker, so to ensure
stable impact, drain the hydraulic oil collected in
the gas chamber each time the pressure is
checked.
• Take the following action according to the results
of the gas pressure measurement.

1. When gas pressure is 0.6 – 1.76 MPa {6 – 18 kg/

cm2} [normal]
1) Screw check adapter 2 (tool supplied with
machine) to pressure gauge 1 (tool supplied
with machine), then push the tip of the check
adapter half way into charging valve (1) and
completely release the gas.
fl When the check adapter is pushed in,
there is danger that hydraulic oil may
spray out from the charging valve, so be
careful not to put your face close to the
valve.
2) Remove charging valve (1) from the hydrau-
lic breaker.
3) Raise the boom and arm, and drain the hy-
draulic oil from the charging valve mounting
hole.
4) After completely draining the hydraulic oil,
install charging valve (1) to the hydraulic
breaker again.
¤ If the charging valve is loose, it will cause
leakage of gas, so be sure to tighten it
securely.
5) Charge the hydraulic breaker with gas. For
details, see CHARGING WITH GAS AND AD-
JUSTING PRESSURE.

2. When gas pressure is 5.9 MPa {6 kg/cm2} and be-

low or 1.77 MPa {18 kg/cm2} and above [abnor-
mal]
fl There is probably a defective seal inside the
breaker, so disassemble and check. For de-
tails, see DISASSEMBLY AND ASSEMBLY OF
fl During the charging operation, a hole is
HYDRAULIC BREAKER ASSEMBLY.
made in the charging cylinder, so after use,
dispose of it as non- combustible garbage.
Charging with gas and adjusting pressure
¤ The charging cylinder is charged with high-pres- 1. Pull up the handle of charging holder 3
sure nitrogen (N2), so if it is subjected to a strong (tool supplied with machine), and set charg-
impact, there is danger that it may rupture. Al- ing cylinder 4 (tool supplied with machine)
ways use great care when handling the charg- inside the holder.
ing cylinder. fl When setting the charging cylinder in-
Do not store the cylinder in direct sunlight. Store side the charging holder, never point
it indoors at a temperature below 40°C. the tip of the holder at any person.

PC27 – 45MRX-1 20-155

 TESTING AND CHARGING PRESSURE OF
TESTING AND ADJUSTING HYDRAULIC BREAKER GAS (N2)

fl The gas charging pressure for each charging cyl-

inder is approx. 5 kg/cm2.
The gas in the charging cylinder is completely re-
leased by a single gas charging operation, so 3
cylinders are needed to charge to the specified
pressure.

2. Tighten the handle of charging holder 3 lightly

and fix charging cylinder 4 in position.

3. Tighten the tip (knurled portion) of charging

holder 3 to the threaded portion of charging valve
(1) to fix it in position.

4. Tighten the handle of charging holder 3 to charge

with gas.
A reaction force is generated when charging with
gas, so hold the equipment securely.

5. After charging, loosen the the tip (knurled por-

tion) of charging holder 3 , then remove the
holder.

6. Repeat Steps 1 to 5 to charge with the gas from 3

charging cylinders 4.

7. Check that the gas pressure has reached the speci-

fied pressure. For details, see MEASURING GAS
PRESSURE. According to the results of the mea-
surement, adjust the gas pressure as shown be-
low.
1) If gas pressure is specified pressure: There is
no need to adjust the gas pressure.
2) If gas pressure is higher than specified pres-
sure:
Use the tip of check adapter 2 screwed into
pressure gauge 1 and push charging valve
(1) lightly to release the gas a little at a time.
Repeat this operation several times to adjust
to the specified pressure.
fl When the check adapter is pushed in,
there is danger that hydraulic oil may
spray out from the charging valve, so be
careful not to put your face close to the
valve.
3) If gas pressure is below specified pressure:
Replace charging cylinder 4 and charge again
with gas.
After charging, measure the gas pressure
again.

20-156 PC27 – 45MRX-1

 ELECTRICAL RELATED PARTS
TESTING AND ADJUSTING PROCEDURE FOR CHECKING DIODE

ELECTRICAL RELATED PARTS

PROCEDURE FOR CHECKING
DIODE
• Check the diode as an individual part and the di-
ode in a wiring harness as follows.
• Use a digital tester with a range for measuring
diodes.

1. Put the red (+) test pin in contact with the anode
(P) of the diode and the black (–) pin in contact
with the cathode (N).
fl There is a mark showing the direction of con-
tinuity on the surface of the diode.
fl When switching to the diode range, normal
testers display the voltage of the internal bat-
tery, but judge the value as follows:
• Does not change → no continuity
• Changes →
there is continuity (normal) (Note)
• The value is 0 or near 0 →
there is a short circuit inside the diode
Note: For silicon diodes, a value of 450 – 600 is
shown.

BLP01357

PC27 – 45MRX-1 20-157

 TROUBLESHOOTING

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

Sequence of events in troubleshooting ................................................................................................ 20-203
Points to remember when carrying out maintenance ......................................................................... 20-204
Checks before troubleshooting .............................................................................................................. 20-212
Connector types and mounting locations ............................................................................................. 20-213
Connector pin allocation drawing .......................................................................................................... 20-216
Connection table for connector pin numbers ....................................................................................... 20-222
Method of using troubleshooting charts ............................................................................................... 20-234
Troubleshooting of electrical system (E mode) .................................................................................... 20-301
Troubleshooting of hydraulic and mechanical system (H mode) ....................................................... 20-401
Troubleshooting of machine monitor system (M mode) ..................................................................... 20-501

PC27 – 45MRX-1 20-201

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are se-
curely fitted.
¤ 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.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it
properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly,
and to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure
and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not 2) Check checking items before starting.
hurry to disassemble the components. 3) Check other checking items.
If components are disassembled immediately 4) Other maintenance items can be checked
any failure occurs: externally, so check any item that is con-
• Parts that have no connection with the fail- sidered to be necessary.
ure or other unnecessary parts will be dis- 4. Confirming failure
assembled. Confirm the extent of the failure yourself,
• It will become impossible to find the cause and judge whether to handle it as a real fail-
of the failure. ure or as a problem with the method of op-
It will also cause a waste of manhours, parts, eration, etc.
or oil or grease, and at the same time, will also fl When operating the machine to reenact
lose the confidence of the user or operator. the troubleshooting symptoms, do not
For this reason, when carrying out trouble- carry out any investigation or measure-
shooting, it is necessary to carry out through ment that may make the problem worse.
prior investigation and to carry out trouble- 5. Troubleshooting
shooting in accordance with the fixed proce- Use the results of the investigation and in-
dure. spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occured apart ing flowchart to locate the position of the
from the problem that had been reported? failure exactly.
2) Was there anything strange about the ma- fl The basic procedure for troubleshooting
chine before tha failure occurred? is as follows.
3) Did the failure occur suddenly, or were 1) Start from the simple points.
there problems with the machine condition 2) Start from the most likely points.
before this? 3) Investigate other related parts or in-
4) Under what conditions did the failure oc- formation.
cur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before the Even if the failure is repaired, if the root cause
failure? of the failure is not repaired, the same fail-
When were these repairs carried out? ure will occur again.
6) Has the same kind of failure occurred be- To prevent this, always investigate why the
fore? problem occureed. Then, remove the root
3. Check before troubleshooting cause.
1) Were there abnormal symptoms about the
machine?

20-202 PC27 – 45MRX-1

TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

TEW00180 TEW00181

Step 1
Examination, confirmation of symptoms

1) When a request for repairs is received, first

ask the following points. Ring Ring
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the TEW00182
failure
• Operating environment
• Past history, details of maintenance, etc. Breakdown

Step 2
Determining probable location of cause TEW00183

1) Look at the troubleshooting section of the

shop manual to find locations of possible Step
causes.
Repair at jobsite

Hurray !
TEW00184 It's repalred

Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in
the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
• Check before starting items
• Other check items
Step 8 2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
Repair at workshop that matches the symptoms, and carry out
troubleshooting.
TEW00187

Step 6
Machine
volume Re-enacting failure

• Drive and operate the machine to confirm

Shop manual the condition and judge if there is really a
failure.
TEW00188

Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.

• Was there anything strange about the ma-

chine before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
TEW00189 failure?

PC27 – 45MRX-1 20-203

TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs 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).

1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT

1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes 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 fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191

Main failures occurring in wiring harness

1 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
oxidization of the contact surfaces.

2 Defective crimping or soldering of connec-

tors
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 plat-
ing at the joint will peel and cause improper
connection or breakage.

20-204 PC27 – 45MRX-1

TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.

TEW00194

4 High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, 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-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.

5 Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.

PC27 – 45MRX-1 20-205

TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors and

wiring harnesses

‡ Disconnecting connectors
1 Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors 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 con-
nectors apart.
fl Never pull with one hand.

2 When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.

TBW00484

Catches

3 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.
fl If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.

TEW00198

20-206 PC27 – 45MRX-1

TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

‡ Connecting connectors
1 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
fl 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 connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
fl If there is any damage or breakage, re-
place the connector.

2 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
TEW00200
3 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 po-
sition.
fl If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.

4 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. TBW00487

PC27 – 45MRX-1 20-207

TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

‡ Drying wiring harness

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

If water gets directly on the connector, do as

follows.
1 Disconnect the connector and wipe off the
water with a dry cloth.
fl If the connector is blown dry with com- TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.

2 Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
fl 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 connec-
tor.

TEW00202

3 Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reas-
semble.

20-208 PC27 – 45MRX-1

TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box

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

TEW00204

3 Do not place objects on top of the control

box.
4 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
5 During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.

TEW00205

6 Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7 Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.

TEW00206

2. Points to remember when troubleshooting electric circuits

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

PC27 – 45MRX-1 20-209

TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.

1) Be careful of the operating environment.

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

2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
TEW00207
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 en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.

TEW00208

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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

TEW00209

20-210 PC27 – 45MRX-1

TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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 pos-
sible 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.

6) Flushing operations
After disassembling and assembling the equip-
ment, 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 sec-
ondary 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 ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.

TEW00211

PC27 – 45MRX-1 20-211

TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Judgement
Item standard Remedy

1. Check fuel level — Add fuel

Lubricating oil, cooling water

2. Check for dirt or water in fuel — Clean, drain

3. Check hydraulic oil level — Add oil

4. Check hydraulic oil strainer — Clean, drain

5. Check hydraulic oil swing machinery — Add oil

6. Check engine oil level (level of oil in oil pan) — Add oil

7. Check cooling water level — Add water

8. Check condition of dust indicator — Clean or replace

9. Check hydraulic oil filter Replace

1. Check for loose or corroded battery terminals — Tighten or replace

equipments
Electrical

2. Check for loose or corroded alternator terminals — Tighten or replace

Check for loose or corroded starting motor

3. terminals — Tighten or replace
Hydraulic, mechani-
cal equipments

1. Check for abnormal noise or smell — Repair

2. Check for oil leakage — Repair

3. Bleed air from system — Bleed air

1. Check battery voltage (engine stopped) 10 – 15 V Replace

2. Check level of battery electrolyte — Add or replace

Electrical components

3. Check for discolored, burnt, or bare wiring — Replace

4. Check for missing wiring clamps, hanging wires — Repair

Checks for getting wet onto wiring Disconnect

5. (check carefully getting wet at connectors — connector and
and terminals) dry connection

6. Check for broken or corroded fuses — Replace

Check alternator voltage  After running 

7. (engine running at over half throttle)  for few min.  Replace
 13.5 – 14.5 V 

20-212 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

CONNECTOR TYPES AND MOUNTING LOCATIONS

PC27, 30MRX-1
fl The address column in this table shows the addres in the conector pin allocation drawing.
Connector

Connector

Connector

Connector
Address

Address
No. of

No. of
Mounting location Mounting location
type

type
pins

pins
No.

No.
Intermediate connector
A1 KES 0 2 (cab specification) L6 M27 Yazaki 2 Fusible link G3
Window washer Intermediate connector
A2 KES 0 2 (cab specification) H8 M28 X 4 (engine) E3

A3 Terminal 1 Cab ground L5 M29 L 2 Fuse B4

Intermediate connector
B3 M 1 (cab specification) K4 M30 M 6 Fuse B4

B4 Yazaki 9 Radio (cab specification) K9 M31 M 2 Engine stop solenoid relay B3

B5 KES 0 2 Speaker L.H. (cab specification) J9 P1 AMP040 16 Monitor panel B7

B6 KES 0 2 Speaker R.H. (cab specification) L8 P2 KES 1 2 PPC lock switch (R.H.) C8
Intermediate connector
B7 M 4 (cab specification) L5 P3 M 2 Horn switch B7
Wiper motor
B8 KES 0 4 (cab specification) H8 P4 KES 1 2 PPC lock switch (L.H.) E5
Intermediate connector
B9 M 1 (cab specification) L5 P5 M 2 Alarm buzzer D8
Room lamp
B10 M 1 (cab specification) K8 P7 KES 1 4 Heater switch (cab specification) E7

D3 KES 1 2 Diode (engine stop solenoid) J9 P8 KES 1 4 Lamp switch E6

Wiper switch
E1 KES 1 2 Alternator I8 P9 KES 1 6 (cab specification) E6

E2 M 1 Alternator (P) I9 R1 Yazaki 2 Engine stop solenoid relay D2

E3 X 3 Engine stop solenoid J2 S3 M 2 Travel boost switch C3

E4 X 2 Engine feed pump L8 T2 Terminal 1 Starting motor (B) K8

Engine water temperature
E7 X 2 sensor H8 T3 Terminal 1 Alternator (B) I9
Intermediate connector
M6 SWP 6 (wiper switch) C2 T4 Connector 1 Starting motor (B) J9
Intermediate connector
M8 Yazaki 2 (lower harness) D2 T5 Terminal 1 Engine oil pressure switch L6
Intermediate connector
M9 SWP 12 (lower harness) E3 T6 Terminal 1 Engine air heater L7
Intermediate connector
M10 X 4 (engine) D3 T7 Connector 1 Horn I2

M11 X 4 Safety relay E4 T8 Terminal 1 Lamp ground G8

Intermediate connector
M12 M 2 (safety relay) E4 T10 Terminal 1 Revolving frame I2

M13 Terminal 1 Safety relay (B) D8 V1 M 2 PPC lock solenoid valve J3

M14 Terminal 1 Safety relay (S) E5 V2 M 2 Travel boost solenoid J3

M16 KES 1 4 Timer B3

Intermediate connector
M17 SWP 6 (cab ground) C2

M18 KES 1 3 Heater (cab ground) B5

M21 X 2 Fuel sensor H8

M23 Connector 1 Working lamp H2

M24 Connector 1 Working lamp H3

M25 Connector 1 Working lamp G7

M26 Connector 1 Working lamp G7

PC27 – 45MRX-1 20-213

TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

PC35MRX-1
fl The address column in this table shows the addres in the conector pin allocation drawing.
Connector

Connector

Connector

Connector
Address

Address
No. of

No. of
Mounting location Mounting location
type

type
pins

pins
No.

No.
Window washer
A1 KES 0 2 (cab specification) H7 S3 X 2 Travel boost switch J2

D1 KES 1 2 Diode (alarm buzzer) F4 T1 Terminal 2 Battery (+) G7

D3 KES 1 2 Diode (engine stop solenoid) L3 T2 Terminal 1 Starting motor (B) L2

E1 KES 1 2 Alternator J8 T3 Terminal 1 Alternator (B) J8

E2 M 1 Alternator (P) K8 T4 Connector 1 Starting motor (S) K2

E3 X 3 Engine stop solenoid L6 T5 Terminal 1 Engine oil pressure switch L4

E4 X 2 Engine feed pump L5 T6 Terminal 1 Engine air heater L6

Engine water temperature
E7 X 2 sensor L8 T7 Connector 1 Horn I2
Intermediate connector
M6 SWP 6 (cab harness) L3 T10 Terminal 1 Revolving frame G6
Intermediate connector
M8 Yazaki 2 (lower harness) H2 T16 Terminal 1 Lamp ground G2
Intermediate connector
M9 SWP 14 (lower harness) I2 T31 Terminal 1 Safety relay (B) A2
Intermediate connector
M10 X 4 (lower harness) H2 T32 Terminal 1 Safety relay (S) A2

M11 X 2 Working lamp H2 V1 X 2 PPC lock solenoid valve J2

M15 X 1 Working lamp G2 V2 X 2 Travel boost solenoid K2

M18 KES 1 3 Heater (cab specification) K2

M20 M 2 Power source (OP) K2

M21 X 2 Fuel sensor H7

M25 Yazaki 12 Fusible link I8

Intermediate connector
M31 X 4 (lower harness) B3
Intermediate connector
M32 X 4 (lower harness) A3

P1 AMP040 16 Monitor panel B9

P2 X 2 PPC lock switch (R.H.) B9

P3 M 2 Horn switch A8

P4 X 2 PPC lock switch (L.H.) F5

P5 M 2 Alarm buzzer F4

P7 KES 1 4 Heater switch (cab specification) F7

P8 KES 1 4 Lamp switch F6

Wiper switch
P9 KES 1 6 (cab specification) F6

R1 X 4 Safety relay A1

R2 Yazaki 2 Engine stop solenoid relay C1

R3 Yazaki 1 Engine stop solenoid relay C3

R4 Yazaki 1 Engine stop solenoid relay D3

R5 KES 1 4 Timer D1

20-214 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTOR PIN ALLOCATION DRAWING

PC27 – 45MRX-1 20-217

TROUBLESHOOTING CONNECTOR PIN ALLOCATION DRAWING

PC35MRX-1

20-218 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTOR PIN ALLOCATION DRAWING

PC27 – 45MRX-1 20-219

TROUBLESHOOTING CONNECTOR PIN ALLOCATION DRAWING

PC40, 45MRX-1

20-220 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. X type connector

of
pins Male (female housing) Female (male housing)

1
1

2
2

TEW00221 TEW00222

1 3 3 1

2 2
TEW00223 TEW00224

1 3
3 1

2 4 4 2

TEW00225 TEW00226

20-222 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. SWP type connector

of
pins Male (female housing) Female (male housing)

1 4 4 1

3 6
6 3 BLP00033
TEW00235

1 5 5 1

4 8 8 4
TEW00237 TEW00238

4 1
1 4
12
8 5
5 8

12 9 9 12
BLP00034 BLP00035

1 4 8 11 11 8 4 1

14

3 7 10 14 14 10 7 3
TEW00239 TEW00240

4 1 4
1

8 5
5 8
16
12 9 9 12

16 13
BLP00036 13 16 BLP00037

PC27 – 45MRX-1 20-223

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. M type connector

of
pins Male (female housing) Female (male housing)

2 2

1 BLP00038 1 BLP00039

2 3 3 2

1 1
TEW00243 TEW00244

1 3 3 1

2 4 4 2
TEW00245 TEW00246

1 4 4 1

3 6 6 3 TEW00248
TEW00247

4 1 4
1

8 5
BLP00040
5 8 BLP00041

20-224 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. S type connector

of
pins Male (female housing) Female (male housing)

1 5 5 1

4 8 TEW00249 8 4 TEW00250

6 1

1 6

10
(White)

5 10 10
TEW00251 5 BLP00042

10
(Blue)

12
(White)

PC27 – 45MRX-1 20-225

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. S type connector

of
pins Male (female housing) Female (male housing)

1 6 6 1

12
(Blue)

5 12
BLP00043
12 5 TEW00254

16
(White)

1 8
8 1

16
(Blue)

7 16 BLP00044 16 7 TEW00256

20-226 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. AMP040 type connector

of
pins Male (female housing) Female (male housing)

4 8
8 4

1 5
5 1 BLP00054
BLP00053

6 12 12 6

12

1 7
BLP00055 7 1 BLP00056

8 16
16 8

16

9 1
1 9
BLP00057 TEW00232

10 20
20 10

20

1 11 11 1
BLP00058 TEW00234

PC27 – 45MRX-1 20-227

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. AMP070 type connector

of
pins Male (female housing) Female (male housing)

12

1 7 7 1

14

6 14 14 BLP00060
BLP00059 6
9 1
1 9

18

8 18 18 BLP00062
BLP00061 8

20

20-228 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. Automobile connector

of
pins Male (female housing) Female (male housing)

2 2

1 1
BLP00063 BLP00064

1
1

3 2
2 3 BLP00065 BLP00066

1 2 2 1

4 3
3 4 BLP00067 BLP00068

1 1 3
3

4 6
6 4 BLP00069 BLP00070

4 1 1 4

5 8
8 5 BLP00071 BLP00072

PC27 – 45MRX-1 20-229

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. MIC type connector

of
pins Male (female housing) Female (male housing)

3 1
1 3

4 5 4
5
5

BLP00045 BLP00046

1 5 5 1

9 9 6
6
9

BLP00047 BLP00048

7 7 1
1

13 13 8
8
13

BLP00049 BLP00050

1 9 9 1

10 17
17 10
17

BLP00051 BLP00052

1 11
11 1

12 21
21 12
21

TEW00259 TEW00260

20-230 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. L type connector

of
pins Male (female housing) Female (male housing)

1 1
2

2 2

TEW00257 TEW00258

No. PA connector
of
pins Male (female housing) Female (male housing)

No. (MS) connector

of
pins Male (female housing) Female (male housing)

10

PC27 – 45MRX-1 20-231

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. Reray connector

of
pins Male (female housing) Female (male housing)

20-232 PC27 – 45MRX-1

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.

No. F type connector

of
pins Male (female housing) Female (male housing)

PC27 – 45MRX-1 20-233

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number

Troubleshooting Code No. Component

E-cc Troubleshooting of electrical system
H-cc Troubleshooting of hydraulic, mechanical system
M-cc Troubleshooting of machine monitor system

2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure
mode (problem with the machine). (See Example (1))
2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ according
to the model, component, or problem. In such cases, the failure mode (problem) is further di-
vided into sections marked with small letters (for example, a)), so go to the appropriate section
to carry out troubleshooting. (See Example (2))
If the troubleshooting table is not divided into sections, start troubleshooting from the first check
item in the failure mode.
3) Method of following troubleshooting chart
YES
• Check or measure the item inside , and according to the answer follow either the YES
NO
line or the NO line to go to the next . (Note: The number written at the top right corner of
the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead
finally to the Cause column. Check the cause and take the action given in the Remedy col-
umn on the right. (See Example (3))
• Below the there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the are correct or the answer to the question
inside the is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item 1).
4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with fl. (See Example (4))
The precautions marked fl are not given in the , but must always be followed when carrying
out the check inside the .
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin num-
ber connection. When carrying out troubleshooting, see this chart for details of the connector
pin number and location for inspection and measurement of the
wiring connector number appearing in the troubleshooting flow chart for each failure mode (prob-
lem).

20-234 PC27 – 45MRX-1

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

<Example>

(1) M-10 Abnormality in coolant temperature gauge

(4) fl When the coolant temperature is normal.
fl Before carrying out troubleshooting, check that all the related connectors are properly in-
serted.
fl Always connect any disconnected connectors before going on the next step.

(2) a) Level does not rise from segment C

(3)
Cause Remedy

YES Defective coolant

Replace
temperature sensor

1 Defective contact or
Does level go up 3 YES disconnection in wiring
one at a time and harness between P1 Repair or replace
finally do all seg- When P1 (6) is (female) (6) – P4 (2) – M1
ments go out YES connected to (5) – E7 (female) (1)
when short con- chassis ground,
2 is condition same
nector is connect-
ed to E7 (female)? Is resistance as in Item 1?
between E7 Defective monitor panel Replace
• Turn starting NO
• Disconnect E7. (female) (2) and
NO chassis ground switch OFF.
• Turn starting
switch ON. normal? Defective contact or
disconnection in wiring
• Turn starting Repair or replace
harness between E7
switch OFF. NO (female) (2) and chassis
• Disconnect E7.
ground
• Max. 1 Ω

M-10 Related electrical circuit diagram

PC27 – 45MRX-1 20-235

TROUBLESHOOTING

TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E MODE)

E-mode related electrical circuit diagram ............................................................................................. 20-302

E-1 Engine does not start ................................................................................................................... 20-308
a) When starting motor does not turn (starting system) ......................................................... 20-308
b) When starting motor turns (engine stop solenoid system) ................................................. 20-311
E-2 Engine does not stop ................................................................................................................... 20-325
E-3 Work equipment does not move even when work equipment lock lever is canceled ........... 20-328
E-4 Work equipment moves even when work equipment lock lever is locked ............................. 20-331
E-5 Travel speed does not increase even when travel boost pedal is depressed ......................... 20-334
E-6 Travel speed does not decrease even when travel boost pedal is released ........................... 20-337

PC27 – 45MRX-1 20-301

TROUBLESHOOTING E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

PC27, 30MRX-1
ENGINE START/STOP SYSTEM

20-302 PC27 – 45MRX-1

TROUBLESHOOTING E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

PPC LOCK, TRAVEL BOOST SOLENOID VALVE SYSTEM

PC27 – 45MRX-1 20-303

TROUBLESHOOTING E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

PC35MRX-1
ENGINE START/STOP SYSTEM

20-304 PC27 – 45MRX-1

TROUBLESHOOTING E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

PPC LOCK, TRAVEL BOOST SOLENOID VALVE SYSTEM

PC27 – 45MRX-1 20-305

TROUBLESHOOTING E-1

Cause Remark

Defective starting motor Replace

Defective contact or
disconnection in wiring
harness between starting Repair or replace
motor terminal B and
battery terminal (+)

Defective battery Replace

Defective contact or
disconnection in wiring
harness between M14 – Repair or replace
M12 (1) – M10 (4) – T4

9 YES
Defective safety relay Replace
Is resistance
between M11
(female) (4) and
chassis ground Defective contact or
normal? disconnection in wiring
harness between M11 Repair or replace
• Max. 1 Ω NO (female) (4) – M17 (5) – A3
• Turn starting – chassis ground
switch OFF.
• Disconnect M11.10 Short circuit with power
YES source in wiring harness
between M11 (female) (3) Repair or replace
Is voltage
between E2 – M28 (3) – E2 (male)
(female) and
chassis ground
normal?
Defective alternator Replace
• Max. 1 V NO
• Disconnect E2.
• Turn starting Defective contact or
switch to ON and disconnection in wiring
START. harness between M11 Repair or replace
(female) (2) and starting
switch terminal C

Go to troubleshooting No. 13.

Defective contact or
disconnection in wiring
harness between M11 Repair or replace
(female) (1) – M30 (4) –
fuse 4 – M29 (2) starting
switch terminal ACC

Defective starting switch Replace

Defective contact or
disconnection in wiring
harness between starting Repair or replace
switch terminal B – M8 (1)
– M72 (2)(1) – battery (+)
Defective contact or
disconnection in wiring
harness between M13 – Repair or replace
M12 (2) – M8 (1) – M27
(2), (1) battery (+)

PC27 – 45MRX-1 20-309

TROUBLESHOOTING E-1

E-1 a) Related electrical circuit diagram

20-310 PC27 – 45MRX-1

 TROUBLESHOOTING E-1

b) When starting motor turns (engine stop solenoid system)

fl Check that fuse 5 is normal (if it is blown, check for a short circuit
with the ground in the circuits related to fuse 5).
fl Before carrying out troubleshooting, check that all the related Cause Remedy
connectors are properly inserted.
fl Always connect any disconnected connectors before going on
the next step. 3 YES Defective engine stop
solenoid Replace
Is resistance
YES between E3
(female) (3) and
Defective contact or
disconnection in wiring
chassis ground harness between E3
2 normal? (female) (3) – T10 – Repair or replace
Is voltage • Max. 1 Ω NO chassis ground
YES between E3 (1) • Turn starting
and chassis switch OFF. Defective contact or
ground as shown • Disconnect E3. disconnection in wiring
in the table? 4 YES harness between E3 Repair or replace
Is voltage (female) (1) – M28
between starting (female) (2) – M30 (1) –
switch terminal fuse 1 – starting switch
NO BR and chassis terminal BR
ground normal?
Defective starting switch Replace
• 10 – 14 V NO
• Turn starting
1 switch ON.

Is voltage 7 YES Defective engine stop Replace

relay
between E3 (2)
and chassis YES Does engine Defective contact or
ground normal? start when C and
D are connected? disconnection in wiring
6 harness between E3
(female) (2) – M28 Repair or replace
Is voltage • Turn starting NO (female) (1) – M31 (1) – D
YES between C switch to START. (female)
(female) and • See Note.
chassis ground Defective contact or
as shown in the 8 YES disconnection in wiring Repair or replace
Is voltage harness between C
• Disconnect C. (female) – M31 (2) – M30
between starting
5 switch terminal (1) – fuse 1 – M29 (1) –
NO BR and chassis starting switch BR
Is voltage ground normal?
between R1 (1) Defective starting switch Replace
• 10 – 14 V NO
NO and (2) as shown
in the table? • Turn starting
switch ON. Defective contact or
disconnection in wiring
YES harness between M16 Repair or replace
9 (female) (1) – R1 (female)
(1) or M16 (female) (2) –
Is voltage R1 (female) (2)
between M16 (1)
NO and (2) as shown 10 YES
in the table? Is voltage Go to A
between M16 (4)
and chassis
NO ground as shown
in the table?
Go to B
NO

11 YES Defective engine stop Replace

Is resistance timer
between M16 (fe-
A male) (3) and Defective contact or
chassis ground disconnection in wiring
normal? harness between M16
(female) (3) – M17 (5) – Repair or replace
• Max. 1 Ω NO A3 – chassis ground
• Turn starting
switch OFF. Defective contact or
• Disconnect M16. disconnection in wiring
12 YES
harness between M16 Repair or replace
Is voltage (female) (4) – M30 (1) –
between starting fuse 1 – M29 (1) – starting
B switch terminal
switch BR
BR and chassis
ground normal? Replace
Defective starting switch
• 10 – 14 V NO
• Turn starting
switch ON.

PC27 – 45MRX-1 20-311

TROUBLESHOOTING E-1

Table
M13 R1, C M16 Starting switch ON

10 – 14 V for 1 second, then

Between (2) – chassis Between R1 (1) – (2) Between (1) – (2) less than 1 V 1 second later

Between C (female) –
Between (1) – chassis chassis Between (4) – chassis 10 – 14 V (continuous)

Note: Connect R3 and R4 for approx. 1 second (if they are kept connected for a long time, it will cause the engine
stop solenoid to burn out).

E-1 b) Related electrical circuit diagram

20-312 PC27 – 45MRX-1

TROUBLESHOOTING

PC27 – 45MRX-1 20-313

TROUBLESHOOTING E-1

PC35MRX-1
a) When starting motor does not turn (starting system)

fl Check that fuse 2 is normal (if it is blown, check for a short circuit with the ground in the circuits
related to fuse 2).
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

YES
2
Is voltage
YES between starting
motor terminal B
and chassis 3 YES
ground normal? Is voltage
between battery
• 10 – 14 V terminal (+) and
• Turn starting NO chassis ground
switch OFF. normal?
• 10 – 14 V NO
• Turn starting
switch OFF.
YES
1
Is voltage
between T4
(male) and
chassis ground
normal?
YES
• 10 – 14 V
• Disconnect T4.
• Turn starting 8
switch to START.
Is voltage
YES between R1 (3)
and chassis
ground normal?
• Max. 1 V
4 7 • Turn starting switch
Is voltage to ON and START.
between safety Is voltage NO
relay terminal S YES between R1 (2)
NO and chassis and chassis
ground normal? ground normal?
• 10 – 14 V • 10 – 14 V
• Turn starting • Turn starting 11 YES
switch to START. switch to START. Is voltage
6 between starting
switch terminal C
Is voltage NO and chassis
YES between R1 (1) ground normal?
and chassis
ground normal? • 10 – 14 V NO
• Turn starting
• 10 – 14 V switch to START.
• Turn starting YES
switch to ON and
START. 12
5 Is voltage
Is voltage between starting
between safety switch terminal
relay terminal B NO ACC and chassis 13 YES
NO and chassis ground normal? Is voltage
ground normal? between starting
• 10 – 14 V switch terminal B
• 10 – 14 V • Turn starting NO and chassis
• Turn starting switch to ON and ground normal?
switch OFF. START.
NO

NO

20-314 PC27 – 45MRX-1

TROUBLESHOOTING E-1

Cause Remark

Defective starting motor Replace

Defective contact or
disconnection in wiring
harness between starting Repair or replace
motor terminal B and
battery terminal (+)

Defective battery Replace

Defective contact or
disconnection in wiring
harness between T32 – Repair or replace
M32 (2) – T4

9 YES
Defective safety relay Replace
Is resistance
between R1
(female) (4) and
chassis ground Defective contact or
normal? disconnection in wiring
harness between R1 Repair or replace
• Max. 1 Ω NO (female) (4) – M31 (4) –
• Turn starting T10 – chassis ground
switch OFF.
• Disconnect R1. 10 Short circuit with power
YES
source in wiring harness Repair or replace
Is voltage between R1 (female) (3) –
between E2 M31 (3) – E2 (female)
(male) and
chassis ground
normal?
Defective alternator Replace
• Max. 1 V NO
• Disconnect E2.
• Turn starting Defective contact or
switch to ON and disconnection in wiring
START. harness between R1 Repair or replace
(female) (2) M31(2) –
M9(3) and starting switch
terminal C

Go to troubleshooting No. 13.

Defective contact or
disconnection in wiring
harness between R1 Repair or replace
(female) (1) – M31(1) –
M9(1) – fuse 3 – starting
switch terminal ACC

Defective starting switch Replace

Defective contact or
disconnection in wiring
harness between starting Repair or replace
switch terminal B – M8 (1)
– M25 (2)(1) – battery (+)
Defective contact or
disconnection in wiring
harness between T31 – Repair or replace
M32(1) – M25(2), (1) –
battery (+)

PC27 – 45MRX-1 20-315

TROUBLESHOOTING E-1

E-1 a) Related electrical circuit diagram

20-316 PC27 – 45MRX-1

 TROUBLESHOOTING E-1

b) When starting motor turns (engine stop solenoid system)

fl Check that fuse 5 is normal (if it is blown, check for a short circuit
with the ground in the circuits related to fuse 5).
fl Before carrying out troubleshooting, check that all the related
Cause Remedy
connectors are properly inserted.
fl Always connect any disconnected connectors before going on
the next step.
3 YES Defective engine stop
solenoid Replace
Is resistance
YES between E3
(female) (3) and
Defective contact or
chassis ground disconnection in wiring
2 normal? harness between E3
(female) (3) – T10 – Repair or replace
Is voltage • Max. 1 Ω NO chassis ground
YES between E3 (1) • Turn starting
and chassis switch OFF. Defective contact or
ground as shown • Disconnect E3. disconnection in wiring
in the table? 4 YES
harness between E3 Repair or replace
Is voltage (female) (1) – M10 (3) –
between starting
switch terminal fuse 1 – starting switch
NO BR and chassis terminal BR
ground normal?
Defective starting switch Replace
• 10 – 14 V NO
• Turn starting
1 switch ON.

Is voltage 7 YES Replace

Defective engine stop
between E3 (2) Does engine relay
and chassis YES start when R3
ground normal? and R4 are Defective contact or
6 connected? disconnection in wiring
harness between E3 Repair or replace
Is voltage • Turn starting NO (female) (2) – M32 (4) –
YES between R3 switch to START. R4 (female)
(female) and • See Note.
chassis ground
as shown in the 8 YES Defective contact or Repair or replace
disconnection in wiring
• Disconnect R3. Is voltage harness between R3
between starting (female) – M32 (3) – M10
5 switch terminal (3) – fuse 1 – starting
NO BR and chassis switch BR
Is voltage ground normal?
between R2 (1) Replace
• 10 – 14 V NO Defective starting switch
NO and (2) as shown
in the table? • Turn starting Defective contact or
switch ON. disconnection in wiring
YES harness between R5
(female) (1) – R2 (female) Repair or replace
9 (1) or R5 (female) (2) – R2
Is voltage (female) (2)
between R5 (1)
NO and (2) as shown 10 YES
in the table? Go to A
Is voltage
between R5 (4)
and chassis
NO ground as shown
in the table? Go to B
NO

11 YES Defective engine stop Replace

Is resistance timer
between R5 (fe-
A male) (3) and Defective contact or
chassis ground disconnection in wiring
normal? harness between R5
(female) (3) – M31 (4) – Repair or replace
• Max. 1 Ω NO T10 – chassis ground
• Turn starting
switch OFF. Defective contact or
• Disconnect R5. disconnection in wiring
12 YES harness between R5 Repair or replace
Is voltage (female) (4) – M32 (3) –
between starting M10 (3) – fuse 1 – starting
B switch terminal
switch BR
BR and chassis
ground normal? Replace
Defective starting switch
• 10 – 14 V NO
• Turn starting
switch ON.

PC27 – 45MRX-1 20-317

TROUBLESHOOTING E-1

Table
M13 R2, R3 R5 Starting switch ON

10 – 14 V for 1 second, then

Between (2) – chassis Between R2 (1) – (2) Between (1) – (2) less than 1 V 1 second later

Between R3 (female)
Between (1) – chassis – chassis Between (4) – chassis 10 – 14 V (continuous)

Note: Connect R3 and R4 for approx. 1 second (if they are kept connected for a long time, it will cause the engine
stop solenoid to burn out).

E-1 b) Related electrical circuit diagram

20-318 PC27 – 45MRX-1

TROUBLESHOOTING

PC27 – 45MRX-1 20-319

TROUBLESHOOTING E-1

Cause Remark

Defective starting motor Replace

Defective contact or
disconnection in wiring
harness between starting Repair or replace
motor terminal B and
battery terminal (+)

Defective battery Replace

Defective contact or
disconnection in wiring
harness between T32 – Repair or replace
M32 (2) – M10

9 YES
Defective safety relay Replace
Is resistance
between R1
(female) (4) and
chassis ground Defective contact or
normal? disconnection in wiring
harness between R1 Repair or replace
• Max. 1 Ω NO (female) (4) – M31 (4) –
• Turn starting T12 – chassis ground
switch OFF.
• Disconnect R1. 10 Short circuit with power
YES source in wiring harness
between R1 (female) (3) – Repair or replace
Is voltage
between M8 M31 (3) – M8 (female)
(female) and
chassis ground
normal?
Defective alternator Replace
• Max. 1 V NO
• Disconnect M8.
• Turn starting Defective contact or
switch to ON and disconnection in wiring
START. harness between R1 Repair or replace
(female) (2) – M31 (2) –
M4 (7) – M54 (12) and
starting switch terminal C

Go to troubleshooting No. 13.

Defective contact or
disconnection in wiring
harness between R1
(female) (1) – M31 (1) – Repair or replace
M4 (6) – M40 (1) – fuse 2
M41 (1) – M55 (3) –
starting switch terminal
Defective starting switch Replace

Defective contact or
disconnection in wiring
harness between starting
switch terminal B – M56 Repair or replace
(2) – M5 (1) – M12 (2)(1) –
battery (+)
Defective contact or
disconnection in wiring Repair or replace
harness between safety
relay terminal B – T31 –
M32 (1) – M12 (2)(1) –
battery (+)

PC27 – 45MRX-1 20-321

TROUBLESHOOTING E-2

E-2 Engine does not stop

PC27, 30MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

Short circuit with power

source in wiring harness
2 YES between E3 (female) (1) –
Is voltage
M28 (2) – M30 (1) – fuse 1 Repair or replace
– starting switch terminal
YES between starting BR, or M16 (female) (4),
switch terminal
1 BR and chassis or C (female)
ground normal?
Does engine stop Defective starting switch Replace
• Max. 1 V NO
when E3 is
disconnected? • Turn starting
switch OFF.

Defective engine stop Replace

NO solenoid

E-2 Related electrical circuit diagram

PC27 – 45MRX-1 20-325

TROUBLESHOOTING E-2

PC35MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

Short circuit with power

source in wiring harness
2 YES between E3 (female) (1) –
M10 (3) – fuse 1 – starting Repair or replace
Is voltage
switch terminal BR, or E3
YES between starting (female) (1) – M32 (3) – R3
switch terminal
1 BR and chassis (female)
ground normal?
Does engine stop Defective starting switch Replace
• Max. 1 V NO
when E3 is
disconnected? • Turn starting
switch OFF.
Defective engine stop
solenoid Replace
NO

E-2 Related electrical circuit diagram

20-326 PC27 – 45MRX-1

TROUBLESHOOTING E-4

E-4 Work equipment moves even when work equipment lock lever is
locked
PC27, 30MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

YES Defective hydraulic

—
2 system
Is resistance
between V1
YES (female) (1) and Short circuit with chassis
chassis ground 3 YES ground in wiring harness Repair or replace
normal? between V1 (female) (1) –
1 Is resistance M9 (10) – P4 (female) (2)
• Min. 1 MΩ between P4
Is resistance • Turn starting (male) (1) and (2)
between V1 NO normal?
switch OFF.
(female) (1) and • Disconnect V1. Defective PPC lock switch Replace
chassis ground • Work equipment • Min. 1 MΩ NO
normal ? lock lever: LOCK • Turn starting switch OFF.
• Min. 1 MΩ • Disconnect P4.
• Turn starting • Work equipment lock lever: LOCK
Defective PPC lock Replace
switch OFF. solenoid
• Disconnect V1. NO

E-4 Related electric circuit diagram

PC27 – 45MRX-1 20-331

TROUBLESHOOTING E-4

PC35MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

YES Defective hydraulic

—
2 system
Is resistance
between V1
YES (female) (1) and Short circuit with chassis
chassis ground 3 YES ground in wiring harness Repair or replace
normal? between V1 (female) (1) –
1 Is resistance M9 (10) – P4 (female) (2)
• Min. 1 MΩ between P4
Is resistance • Turn starting (male) (1) and (2)
between V1 NO normal?
switch OFF.
(female) (1) and • Disconnect V1. Defective PPC lock switch Replace
chassis ground • Work equipment • Min. 1 MΩ NO
normal ? lock lever: LOCK • Turn starting switch OFF.
• Min. 1 MΩ • Disconnect P4.
• Turn starting • Work equipment lock lever: LOCK
Defective PPC lock Replace
switch OFF. solenoid
• Disconnect V1. NO

E-4 Related electric circuit diagram

20-332 PC27 – 45MRX-1

TROUBLESHOOTING E-4

PC40, 45MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

YES Defective hydraulic

—
2 system
Is resistance
between V1
YES (female) (1) and Short circuit with chassis
chassis ground 3 YES ground in wiring harness Repair or replace
normal? between V1 (female) (1) –
1 Is resistance V5 (female) (2)
• Min. 1 MΩ between V5
Is resistance • Turn starting (male) (1) and (2)
between V1
NO normal?
switch OFF.
(female) (1) and • Disconnect V1. Defective PPC lock switch Replace
chassis ground • Work equipment • Min. 1 MΩ NO
normal ? lock lever: LOCK • Turn starting switch OFF.
• Disconnect V5.
• Min. 1 MΩ • Work equipment lock lever: LOCK
• Turn starting Defective PPC lock Replace
switch OFF. solenoid
• Disconnect V1.
NO

E-4 Related electric circuit diagram

PC27 – 45MRX-1 20-333

 TROUBLESHOOTING E-5

E-5 Travel speed does not increase even when travel boost pedal is
depressed
PC27, 30MRX-1
fl Check that fuse 3 is normal (if it is blown, check for a short circuit with the ground in the circuits
related to fuse 3).
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

YES Defective hydraulic —

3 system
Is resistance
YES between V2
(female) (1) and
chassis ground 4 YES Go to Troubleshooting
normal? Item No. 6
Is resistance
• Max. 1 Ω between S3
• Turn starting NO (male) (1) – (2)
2 switch OFF. normal?
YES Is voltage Defective travel boost Replace
• Disconnect V2.
between V2 • Travel boost • Max. 1 Ω NO switch
(female) (2) and pedal: Depressed • Turn starting switch
chassis ground OFF.
normal? • Disconnect S3.
• Travel boost pedal: Defective contact or
• 10 – 14 V Depressed disconnection in wiring
1 • Disconnect V2. 5 YES harness between starting
• Turn starting switch terminal ACC – Repair or replace
Is resistance Is voltage
switch ON. between starting M29 (2) – fuse 3 – M30 (3)
between V2 – M9 (1) – V2 (female) (2)
(male) (1) and (2) switch terminal
NO ACC and chassis
normal? ground normal?
Defective starting switch Replace
• 5 – 25 Ω •10 – 14 V NO
• Turn starting • Turn starting
switch OFF. switch ON.
• Disconnect V2.
Defective travel boost Replace
NO solenoid

Defective contact or
YES disconnection in wiring
6 harness between S3 Repair or replace
Is resistance (female) (1) – M9 (9) – V2
between S3 (female) (1)
(female) (2) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or replace
• Max. 1 Ω NO harness between S3
• Turn starting (female) (2) – M9 (3) – T10
switch OFF.
• Disconnect S3.

E-5 Related electric circuit diagram

20-334 PC27 – 45MRX-1

 TROUBLESHOOTING E-5

PC35MRX-1
fl Check that fuse 3 is normal (if it is blown, check for a short circuit with the ground in the circuits
related to fuse 3).
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

YES Defective hydraulic —

3 system
Is resistance
YES between V2
(female) (1) and
chassis ground 4 YES Go to Troubleshooting
normal? Item No. 6
Is resistance
• Max. 1 Ω between S3
• Turn starting NO (male) (1) – (2)
2 switch OFF. normal?
YES Is voltage Defective travel boost Replace
• Disconnect V2.
between V2 • Travel boost • Max. 1 Ω NO switch
(female) (2) and pedal: Depressed • Turn starting switch
chassis ground OFF.
normal? • Disconnect S3.
• Travel boost pedal: Defective contact or
• 10 – 14 V Depressed disconnection in wiring
1 • Disconnect V2. 5 YES harness between starting
• Turn starting switch terminal ACC – Repair or replace
Is resistance Is voltage
switch ON. between starting fuse 3 – M9 (1) – V2
between V2 (female) (2)
(male) (1) and (2) switch terminal
NO ACC and chassis
normal? ground normal?
Defective starting switch Replace
• 5 – 25 Ω •10 – 14 V NO
• Turn starting • Turn starting
switch OFF. switch ON.
• Disconnect V2.
Defective travel boost Replace
NO solenoid

Defective contact or
YES disconnection in wiring
6 harness between S3 Repair or replace
Is resistance (female) (1) – M9 (9) – V2
between S3 (female) (1)
(female) (1) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or replace
• Max. 1 Ω NO harness between S3
• Turn starting (female) (2) – M9 (3) – T10
switch OFF.
• Disconnect S3.

E-5 Related electric circuit diagram

PC27 – 45MRX-1 20-335

 TROUBLESHOOTING E-5

PC40, 45MRX-1
fl Check that fuse 4 is normal (if it is blown, check for a short circuit with the ground in the circuits
related to fuse 4).
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

YES Defective hydraulic —

3 system
Is resistance
YES between V3
(female) (1) and
chassis ground 4 YES Go to Troubleshooting
normal? Item No. 6
Is resistance
• Max. 1 Ω between S5
• Turn starting NO (male) (1) – (2)
2 switch OFF. normal?
YES Is voltage Defective travel boost Replace
• Disconnect V3.
between V3 • Travel boost • Max. 1 Ω NO switch
(female) (2) and pedal: Depressed • Turn starting switch
chassis ground OFF.
normal? • Disconnect S5.
• Travel boost pedal: Defective contact or
• 10 – 14 V Depressed disconnection in wiring
1 • Disconnect V3. 5 YES harness between starting
• Turn starting switch terminal ACC – Repair or replace
Is resistance Is voltage
switch ON. between starting M55 (3) – M41 (1) – fuse 4
between V3 – M40 (3) – V3 (female) (2)
(male) (1) and (2) switch terminal
NO ACC and chassis
normal? ground normal?
Defective starting switch Replace
• 5 – 25 Ω •10 – 14 V NO
• Turn starting • Turn starting
switch OFF. switch ON.
• Disconnect V3.
Defective travel boost Replace
NO solenoid

Defective contact or
YES disconnection in wiring
6 harness between S5 Repair or replace
Is resistance (female) (2) – V3 (female)
between S5 (1)
(female) (1) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or replace
• Max. 1 Ω NO harness between S5
• Turn starting (female) (1) – M5 (2) – T12
switch OFF.
• Disconnect S5.

E-5 Related electric circuit diagram

20-336 PC27 – 45MRX-1

TROUBLESHOOTING E-6

E-6 Travel speed does not decrease even when travel boost pedal is
released
PC27, 30MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

YES Defective hydraulic

2 system —
Is resistance
between V2
YES (female) (1) and Defective contact or
chassis ground 3 YES disconnection in wiring
Is resistance harness between V2 Repair or replace
normal?
1 between S3 (female) (1) – M9 (9) and
Is resistance • Min. 1 MΩ (male) (1) – (2) S3 (female) (1)
between V2 • Turn starting NO and chassis
(male)(1) and switch OFF. ground normal? Defective travel boost
• Disconnect V2. Replace
chassis ground • Min. 1 MΩ NO switch
normal? • Travel boost • Turn starting
switch: Released switch OFF.
• Min. 1 MΩ
• Turn starting • Disconnect S3.
• Travel boost switch: Released Defective travel boost
switch OFF. Replace
• Disconnect V2. NO solenoid

E-6 Related electric circuit diagram

PC27 – 45MRX-1 20-337

TROUBLESHOOTING E-6

PC35MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

YES Defective hydraulic

2 system —
Is resistance
between V2
YES (female) (1) and Defective contact or
chassis ground 3 YES disconnection in wiring
Is resistance harness between V2 Repair or replace
normal?
1 between S3 (female) (1) – M9 (9) and
Is resistance • Min. 1 MΩ (male) (1) – (2) S3 (female) (2)
between V2 • Turn starting NO and chassis
(male) (1) and switch OFF. ground normal? Defective travel boost
• Disconnect V2. Replace
chassis ground • Min. 1 MΩ NO switch
normal? • Travel boost • Turn starting
switch: Released switch OFF.
• Min. 1 MΩ
• Turn starting • Disconnect S3.
• Travel boost switch: Released Defective travel boost
switch OFF. Replace
• Disconnect V2. NO solenoid

E-6 Related electric circuit diagram

20-338 PC27 – 45MRX-1

TROUBLESHOOTING E-6

PC40, 45MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

YES Defective hydraulic

2 system —
Is resistance
between V3
YES (female) (1) and Defective contact or
chassis ground 3 YES disconnection in wiring
Is resistance harness between V3 Repair or replace
normal?
1 between S5 (female) (1) – S5 (female)
Is resistance • Min. 1 MΩ (male) (1) – (2) (2)
between V3 • Turn starting NO and chassis
(male) (1) and switch OFF. ground normal? Defective travel boost
• Disconnect V3. Replace
chassis ground • Min. 1 MΩ NO switch
normal? • Travel boost • Turn starting
switch: Released switch OFF.
• Min. 1 MΩ
• Turn starting • Disconnect S5.
• Travel boost switch: Released Defective travel boost
switch OFF. Replace
• Disconnect V3. NO solenoid

E-6 Related electric circuit diagram

PC27 – 45MRX-1 20-339

TROUBLESHOOTING

TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)

Table of failure modes and causes ........................................................................................................ 20-402

H- 1 Speeds of all work equipment, swing, travel are slow or lack power ..................................... 20-406
H- 2 There is excessive drop in engine speed, or engine stalls ....................................................... 20-409
H- 3 No work equipment, travel, swing move ................................................................................... 20-412
H- 4 Abnormal noise generated (from around pump) ...................................................................... 20-413
H- 5 Fine control ability is poor or response is poor ......................................................................... 20-414
H- 6 Boom is slow or lacks power ....................................................................................................... 20-415
H- 7 Arm is slow or lacks power ......................................................................................................... 20-417
H- 8 Bucket is slow or lacks power ..................................................................................................... 20-419
H- 9 Boom swing is slow or lacks power ........................................................................................... 20-421
H-10 Blade is slow or lacks power ....................................................................................................... 20-424
H-11 Boom, arm, bucket do not move (boom swing, blade, travel and swing are normal) ........... 20-425
H-12 Excessive hydraulic drift (boom, arm, bucket, boom swing, blade) ........................................ 20-426
a) Boom ........................................................................................................................................ 20-426
b) Arm, bucket, boom swing ...................................................................................................... 20-426
c) Blade ........................................................................................................................................ 20-426
H-13 Excessive time lag (engine at low idling) ................................................................................... 20-427
H-14 In compound operations, work equipment with larger load is slow ....................................... 20-427
H-15 Travel deviation ............................................................................................................................ 20-428
a) When there is during normal travel ...................................................................................... 20-428
b) There is deviation machine moves off .................................................................................. 20-428
H-16 Travel speed is slow or lacks power ........................................................................................... 20-431
H-17 Steering does not turn easily ...................................................................................................... 20-432
H-18 Travel speed does not switch ...................................................................................................... 20-432
H-19 Travel does not move (one side only) ........................................................................................ 20-432
H-20 Swing speed is slow or lacks power ........................................................................................... 20-433
a) Speed is slow or lacks power in both directions .................................................................. 20-433
b) Speed is slow or lacks power in one direction only (left or right) ...................................... 20-433
H-21 Does not swing ............................................................................................................................. 20-435
a) Does not swing in either direction ......................................................................................... 20-435
b) Does not swing in one direction (left or right) ...................................................................... 20-435
H-22 Swing acceleration is poor .......................................................................................................... 20-436
a) Acceleration is poor in both directions ................................................................................. 20-436
b) Acceleration is poor in one direction only (left or right) ...................................................... 20-436
H-23 Excessive overrun when stopping swing ................................................................................... 20-437
a) Overrun when stopping is excessive in both directions ...................................................... 20-437
b) Overrun when stopping is excessive in one direction only (left or right) .......................... 20-437
H-24 Excessive shock when stopping swing (in one direction only) ................................................ 20-438
H-25 Excessive abnormal noise when stopping swing ...................................................................... 20-438
H-26 Excessive hydraulic drift of swing .............................................................................................. 20-438

PC27 – 45MRX-1 20-401

TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES

TABLE OF FAILURE MODES AND CAUSES

PC27, 30MRX-1
Hydraulic
pump Control valve
Parts causing failure

Self pressure reducing valve

Main relief valve

Sequence valve
Unload valve
Servo piston
Piston pump
Gear pump
PC valve
LS valve
Damper
Strainer

Spool
Failure mode

Speeds of all work equipment, swing, travel are slow or lack power b b b b b b b
travel, swing
equipment,

b b b b
All work

There is excessive drop in engine speed, or engine stalls

No work equipment, travel, swing move b b b
Abnormal noise generated (around pump) b b
Fine control ability is poor or response is poor b b b b b
Boom is slow or lacks power b
Arm is slow or lacks power b
Bucket is slow or lacks power b
Boom swing is slow or lacks power b
Blade is slow or lacks power b
Work equipment

Boom does not move b

Arm does not move b
Bucket does not move b
Boom b
Arm b
Excessive hydraulic drift Bucket b
Boom swing b
Blade b
Excessive time lag
In compound operations, work equipment with larger load is slow
Deviation during normal travel b
Travel system

Travel deviation
Deviation when starting
Travel speed is slow or lacks power b b b
Steering does not turn easily b
Travel speed does not switch
Travel does not move (one side only)
Both left and right b
Swing speed is slow or lacks power
One direction only b
Both left and right b
Does not swing
Swing system

One direction only b

Both left and right
Swing acceleration is poor
One direction only b
Both left and right
Excessive overrun when stopping swing
One direction only b
Excessive shock when stopping swing (one direction only) b
Excessive abnormal noise when stopping swing
Excessive hydraulic drift of swing

20-402 PC27 – 45MRX-1

 b
b
b
b
b
b
b
Pressure compensation valve

b
b
b
b
Central safety valve
Check valve

b
b
b
b
b
b
b
b
b
Suction valve

b
b
Load check valve

Control valve

b
Lift check valve

PC27 – 45MRX-1
b
b
PPC lock solenoid
noid

b
Travel boost solenoid
valve
Sole-
TROUBLESHOOTING

b
b
b
b
b
b
b
b
b
PPC valve

b
b b
b
Swing show retura valve

b
b
Swing holding brake

b b
b
Safety valve

b b
b
Check valve

b b
Suction valve
Swing motor

b
b
b
Motor proper

b
b b
Swing machinery

b
Center swivel joint

b
b
b
Counterbalance valve
Check valve

b
Speed selector servo
Motor proper
Travel motor

b b
b b
Final drive

b
b
b
b
b
b
Hydraulic cylinder

b
b b
b b
Control valve
b

Engine system

H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
mode

H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-11
H-10
Trouble-
shooting

20-403
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES

PC35, 40, 45MRX-1

Hydraulic Control
pump valve
Parts causing failure

Pressure compensation vavle

Main relief valve
Unload valve
Servo piston
Piston pump
Gear pump
PPC pump
PC valve
LS valve
Damper
Strainer

Spool
Failure mode

Speeds of all work equipment, swing, travel are slow or lack power b b b b b
travel, swing
equipment,

b b b
All work

There is excessive drop in engine speed, or engine stalls

No work equipment, travel, swing move b b b b
Abnormal noise generated (around pump) b b
Fine control ability is poor or response is poor b b b b b
Boom is slow or lacks power b b
Arm is slow or lacks power b b
Bucket is slow or lacks power b b
Boom swing is slow or lacks power b b
Blade is slow or lacks power b
Work equipment

Boom does not move b

Arm does not move b
Bucket does not move b
Boom b
Arm b
Excessive hydraulic drift Bucket b
Boom swing b
Blade b
Excessive time lag
In compound operations, work equipment with larger load is slow b
Deviation during normal travel b b b
Travel system

Travel deviation Deviation when starting

Deviates in same direction in forward and reverse b
Travel speed is slow or lacks power b b
Steering does not turn easily b b
Travel speed does not switch
Travel does not move (one side only)
Both left and right b
Swing speed is slow or lacks power
One direction only b
Both left and right b
Does not swing
Swing system

One direction only b

Both left and right
Swing acceleration is poor
One direction only b
Both left and right
Excessive overrun when stopping swing
One direction only b
Excessive shock when stopping swing (one direction only) b
Excessive abnormal noise when stopping swing
Excessive hydraulic drift of swing

20-404 PC27 – 45MRX-1

 b
b
b
b
b
Central safety vavle
Check valve

b
b
b
b
b
b
b
b
b
b
b
Suction valve

b
b
Load check vavle

b
Lift check valve

PC27 – 45MRX-1
b
PPC lock solenoid

Control valve noid

b
valve
Travel boost solenoid Sole-

b
b
b
b
b
b
b
b
PPC valve
TROUBLESHOOTING

b
b b
b
Swing slow return vavle

b
b
Swing holding brake

b
b b
b
b
Safety valve

b
Check valve

b
b b
Suction valve
Swing motor

b b
b
b
b
Motor proper

b b
Swing machinery

b
b
Center swivel joint

b
b
Counterbalance valve
Check valve

b
Speed selector servo
Motor proper
Travel motor

b b
b b
Final drive

b
b
b
b
b
b
Hydraulic cylinder

b
b b
b b
b Control valve
Engine system
mode

H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1

H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-11
H-10
Trouble-
shooting

20-405
TABLE OF FAILURE MODES AND CAUSES
 TROUBLESHOOTING H-1

H-1 Speeds of all work equipment, swing, travel are slow or lack power
PC27MRX-1
fl Carry out this troubleshooting if the actuators in 2 or more systems are slow or lack power at the
same time.

Cause Remedy

YES
Defective sequence valve Repair or replace

2
4 YES Adjust
Does problem Defective adjustment of
YES disappear when Does condition PC valve
engine speed is YES become normal
raised? when PC valve is
3 adjusted?
Go to A
Is work NO
equipment, travel
relief pressure
NO normal?
1 5 YES
Go to B
• 22.06 ± 0.49MPa
Is PPC lock
solenoid valve {225 ± 5 kg/cm2} Is unload oil
output pressure • Engine at high pressure normal?
NO
normal? idling
Defective unload valve Repair or replace
• 2.94 +0.49
–0.1 MPa
• 4.41 ± 0.49 MPa NO
{30 +5 2
–1 kg/cm }
{45 ± 5 kg/cm2}
• Engine at high • Engine at high
idling idling
YES Replace
Defective PPC lock
solenoid valve
6

Is control circuit Defective adjustment of

oil pressure YES Adjust
self pressure reducing
NO normal? 7 valve
Does condition
become normal
when self pres-
NO sure reducing 8 YES Defective self pressure
reducing valve (piston Repair or replace
valve is adjusted? Does condition valve)
become normal
when relief valve
NO of self pressure Defective self pressure
reducing valve is
reducing valve (relief Repair or replace
NO valve)

9 YES Defective PC valve, servo Repair or replace

Does condition piston
A become normal
when PC valve,
servo piston are
replaced?
Defective piston pump Repair or replace
NO

10 YES Adjust
Defective adjustment of
Does condition main relief valve
B become normal
when main relief
valve is adjusted?
Defective main relief Repair or replace
NO valve

20-406 PC27 – 45MRX-1

 TROUBLESHOOTING H-1

PC30MRX-1
fl Carry out this troubleshooting if the actuators in 2 or more systems are slow or lack power at the
same time.

Cause Remedy

YES
Defective sequence valve Repair or replace

2
4 YES Adjust
Does problem Defective adjustment of
YES disappear when Does condition PC valve
engine speed is YES become normal
raised? when PC valve is
3 adjusted?
Go to A
Is work NO
equipment, travel
relief pressure
NO normal?
1 5 YES
Go to B
• 25.5 ± 0.49MPa
Is PPC lock
solenoid valve {260 ± 5 kg/cm2} Is unload oil
output pressure • Engine at high pressure normal?
NO
normal? idling
Defective unload valve Repair or replace
• 2.94 +0.49
–0.1 MPa
• 4.41 ± 0.49 MPa NO
{30 +5 2
–1 kg/cm }
{45 ± 5 kg/cm2}
• Engine at high • Engine at high
idling idling
YES Replace
Defective PPC lock
solenoid valve
6

Is control circuit Defective adjustment of

oil pressure YES Adjust
self pressure reducing
NO normal? 7 valve
Does condition
become normal
when self pres-
NO sure reducing 8 YES Defective self pressure
reducing valve (piston Repair or replace
valve is adjusted? Does condition valve)
become normal
when relief valve
NO of self pressure Defective self pressure
reducing valve is
reducing valve (relief Repair or replace
NO valve)

9 YES Defective PC valve, servo Repair or replace

Does condition piston
A become normal
when PC valve,
servo piston are
replaced?
Defective piston pump Repair or replace
NO

10 YES Adjust
Defective adjustment of
Does condition main relief valve
B become normal
when main relief
valve is adjusted?
Defective main relief Repair or replace
NO valve

PC27 – 45MRX-1 20-407

TROUBLESHOOTING H-1

PC35, 40, 45MRX-1

Cause Remedy

YES Defective adjustment of Adjust

3 PC valve
Does condition
YES become normal
when PC valve is 4 YES Defective PC valve, servo
adjusted? Repair or replace
piston
Does condition
become normal
NO when PC valve is
2 adjusted?
Defective piston pump Repair or replace
Is work NO
YES equipment, travel
relief pressure
normal?
6 YES Defective adjustment of
Adjust
• 26.3 ± 0.49 MPa Does condition main relief valve
{268 ± 5 kg/cm2} YES become normal
1 • Engine at high 5 when main relief
idling valve is
adjusted? Defective main relief
Is control pump Repair or replace
output pressure Is unload oil NO valve
normal? NO pressure normal?

• 2.94 +0.49
–0.1 MPa • 3.2 ± 0.49 MPa
{30 +5 2
–1 kg/cm } {33 ± 5 kg/cm2} Defective unload valve Repair or replace
NO
• Engine at high • Engine at high
idling idling

Go to H-3 —
NO

20-408 PC27 – 45MRX-1

 TROUBLESHOOTING H-2

H-2 There is excessive drop in engine speed, or engine stalls

PC27MRX-1

Cause Remedy

YES Clogged piston pump Clean

3 orifice plug

YES Is orifice plug of

piston pump
clogged? 4 YES Defective adjustment of PC Adjust
valve
Does condition
become normal
2
NO when PC valve is
adjusted?
Go to A
YES Is swing relief • See Note
pressure normal? NO

• 18.0 +0.49
–0 MPa 5 YES Defective adjustment of Adjust
{184 +5
–0 kg/cm }
2
Does condition swing motor safety valve
1 • Engine at high become normal
Is work idling when swing
equipment, travel NO motor safety valve
relief pressure is adjusted? Defective swing motor
safety valve Repair or replace
normal? NO
• 22.06 ± 0.49 MPa
{225 ± 5 kg/cm2}
• Engine at high 6 YES Defective adjustment of Adjust
idling Does condition main relief valve
become normal
when main relief
NO valve is
adjusted?
Defective main relief valve Repair or replace
• See Note NO

7 YES Defective PC valve, servo Repair or replace

Does condition piston
become normal
A when PC valve,
servo piston are
replaced? See Engine
Defective engine system
NO Shop Manual
• See Note

Note: To judge, measure the engine speed during 1-pump relief or 2-pump relief.

1-pump relief 2-pump relief

Min. 2,500 rpm Min. 2,000 rpm

PC27 – 45MRX-1 20-409

 TROUBLESHOOTING H-2

PC30MRX-1

Cause Remedy

YES Clogged piston pump Clean

3 orifice plug

YES Is orifice plug of

piston pump
clogged? 4 YES Defective adjustment of PC Adjust
valve
Does condition
become normal
2 NO when PC valve is
adjusted?
YES Is swing relief Go to A
pressure normal? • See Note NO

• 18.0 +0.49
–0 MPa 5 YES Defective adjustment of Adjust
{184 +5
–0 kg/cm }
2
Does condition swing motor safety valve
1 • Engine at high become normal
Is work idling when swing
equipment, travel NO motor safety valve
relief pressure is adjusted? Defective swing motor
safety valve Repair or replace
normal? NO
• 25.5 ± 0.49 MPa
{260 ± 5 kg/cm2}
• Engine at high 6 YES Defective adjustment of Adjust
idling Does condition main relief valve
become normal
when main relief
NO valve is
adjusted?
Defective main relief valve Repair or replace
• See Note NO

7 YES Defective PC valve, servo Repair or replace

Does condition piston
become normal
A when PC valve,
servo piston are
replaced? See Engine
Defective engine system
NO Shop Manual
• See Note

Note: To judge, measure the engine speed during 1-pump relief or 2-pump relief.

1-pump relief 2-pump relief

Min. 2,500 rpm Min. 2,060 rpm

20-410 PC27 – 45MRX-1

 TROUBLESHOOTING H-2

PC35, 40, 45MRX-1

Cause Remedy

YES Clogged piston pump Clean

3 orifice plug

YES Is orifice plug of

piston pump
clogged? 4 YES Defective adjustment of PC Adjust
valve
Does condition
become normal
2 NO when PC valve is
adjusted?
YES Is swing relief Go to A
pressure normal? • See Note NO

PC35MRX-1 5 YES Defective adjustment of Adjust

• 18.6 ± 0.98 MPa Does condition swing motor safety valve
1 {190 ± 10 kg/cm2} become normal
• Engine at high when swing
Is work idling
equipment, travel NO motor safety valve
PC40, 45MRX-1 is adjusted? Defective swing motor
relief pressure • 21.0 ± 0.98 MPa Repair or replace
normal? safety valve
{215 ± 10 kg/cm2} NO
• Engine at high
• 26.3 ± 0.49 MPa idling
{268 ± 5 kg/cm2}
• Engine at high 6 YES Defective adjustment of Adjust
idling Does condition main relief valve
become normal
when main relief
NO valve is
adjusted?
Defective main relief valve Repair or replace
• See Note NO

7 YES Defective PC valve, servo Repair or replace

Does condition piston
become normal
A when PC valve,
servo piston are
replaced? See Engine
Defective engine system
NO Shop Manual
• See Note

Note: To judge, measure the engine speed during 1-pump relief or 2-pump relief.

1-pump relief 2-pump relief

Min. 2,060 rpm Min. 2,060 rpm

PC27 – 45MRX-1 20-411

 TROUBLESHOOTING H-3

H-3 No work equipment, travel, swing move

PC27, 30MRX-1
fl Carry out this troubleshooting if the actuators in 2 or more systems are slow or lack power at the
same time.

Cause Remedy

YES Defective PPC lock

solenoid valve Repair or replace
1

Is control circuit
oil pressure Defective self pressure
normal? YES reducing valve (piston Repair or replace
2 valve)
• 294 +0.49
MPa
–0.1 Does oil come
{30 kg/cm2}
+5 out when pump
–1
• Engine at high pressure
NO measurement 3 YES
idling Defective piston pump Repair or replace
plug is removed?
Does piston
• Crank engine by pump shaft
hand. NO rotate?
Defective damper Repair or replace
• Remove gear pump.NO
• Crank engine by hand.

PC35, 40, 45MRX-1

Cause Remedy

YES Defective PPC lock

solenoid valve Repair or replace
1

Is control circuit
oil pressure Defective self pressure
normal? YES reducing valve (piston Repair or replace
2 valve)
• 294 +0.49
MPa
–0.1 Does oil come
{30 kg/cm2}
+5 out when pump
–1
• Engine at high pressure
NO measurement 3 YES
idling Defective piston pump Repair or replace
plug is removed?
Does piston
• Crank engine by pump shaft
hand. NO rotate?
Defective damper Repair or replace
• Remove gear pump.NO
• Crank engine by hand.

20-412 PC27 – 45MRX-1

TROUBLESHOOTING H-4

H-4 Abnormal noise generated (from around pump)

PC27, 30, 35, 40, 45MRX-1

Cause Remedy

3 YES Go to
Troubleshooting
Do bubbles No. 4
YES disappear when
engine is
stopped?
Change
2 Improper hydraulic oil hydraulic oil
NO
YES Are there
bubbles inside
hydraulic tank? YES Suction strainer clogged
by external foreign Remove
4 material (cloth, etc.)
Is suction
1 strainer clogged
with external 5 YES Repair or replace
NO foreign material? Defect inside pump
Is hydraulic tank Is suction strainer
oil level correct? clogged with
ª External foreign metal particles or
material: cloth, other foreign ma-
etc.
NO terial, or are there
metal particles Inspect again
stuck to it? Operate for a short time (according to
NO and look for any change change in
in the condition condition)
Lack of hydraulic oil Add hydraulic
NO oil

PC27 – 45MRX-1 20-413

TROUBLESHOOTING H-5

H-5 Fine control ability is poor or response is poor

PC27, 30, 35, 40, 45MRX-1

Cause Remedy

YES Clogged unload valve Clean

2 orifice

YES Is unload valve

orifice clogged? 3 YES
Clogged piston pump Clean
orifice plug
Is piston pump
orifice plug
1 NO clogged?
Is LS differential Defective PC valve, servo Repair or replace
pressure nor- NO piston
mal?

• See TESTING 4 YES

Defective adjustment of Adjust
AND ADJUSTING. Does condition LS valve
become normal
when LS valve is
NO adjusted?
Defective LS valve Repair or replace
NO

20-414 PC27 – 45MRX-1

TROUBLESHOOTING H-6

H-6 Boom is slow or lacks power

PC27MRX-1
Cause Remedy

4 YES
Defective boom cylinder Repair or replace
Does pressure packing
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or replace
YES Does control NO valve
valve spool
move smoothly?
2

YES Is output NO
Defective operation of Repair or replace
pressure of PPC control valve spool
valve normal?
1
• 2.94 +0.49
–0.1 MPa
{30 +5 2 Defective PPC valve Repair or replace
–1 kg/cm } NO
Is boom relief • Engine at high
pressure normal? idling
5 YES
• 22.06 ± 0.49MPa Defective suction valve Repair or replace
{225 ± 5 kg/cm2} Is arm relief
• Engine at high pressure
idling NO normal?
Defective central safety Replace
• 22.06 ± 0.49MPa NO valve
{225 ± 5 kg/cm2}
• Engine at high
idling

PC30MRX-1
Cause Remedy

4 YES
Defective boom cylinder Repair or replace
Does pressure packing
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or replace
YES Does control NO valve
valve spool
move smoothly?
2

YES Is output NO
Defective operation of Repair or replace
pressure of PPC control valve spool
valve normal?
1
• 2.94 +0.49
–0.1 MPa
{30 +5 2 Defective PPC valve Repair or replace
–1 kg/cm } NO
Is boom relief • Engine at high
pressure normal? idling
5 YES
• 25.5 ± 0.49MPa Defective suction valve Repair or replace
{260 ± 5 kg/cm2} Is arm relief
• Engine at high pressure
idling NO normal?
Defective central safety Replace
• 25.5 ± 0.49MPa NO valve
{260 ± 5 kg/cm2}
• Engine at high
idling

PC27 – 45MRX-1 20-415

TROUBLESHOOTING H-6

PC35, 40, 45MRX-1

Cause Remedy

4 YES
Defective boom cylinder Repair or replace
Does pressure packing
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or replace
YES Does control NO valve
valve spool
move smoothly?
2

YES Is output NO
Defective operation of Repair or replace
pressure of PPC control valve spool
valve normal?
1
• 2.94 +0.49
–0.1 MPa
{30 +5 2 Defective PPC valve Repair or replace
–1 kg/cm } NO
Is boom relief • Engine at high
pressure normal? idling
5 YES
• 26.3 ± 0.49MPa Defective suction valve Repair or replace
{268 ± 5 kg/cm2} Is arm relief
• Engine at high pressure
idling NO normal?
Defective central safety Replace
• 26.3 ± 0.49MPa NO valve
{268 ± 5 kg/cm2}
• Engine at high
idling

20-416 PC27 – 45MRX-1

TROUBLESHOOTING H-7

H-7 Arm is slow or lacks power

PC27MRX-1
Cause Remedy

4 YES
Defective arm cylinder Repair or replace
Does pressure packing
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or replace
YES Does control NO valve
valve spool
move smoothly?
2

YES Is output NO
Defective operation of Repair or replace
pressure of PPC control valve spool
valve normal?
1
• 2.94 +0.49
–0.1 MPa
{30 +5 2 Defective PPC valve Repair or replace
–1 kg/cm } NO
Is arm IN relief • Engine at high
pressure normal? idling
5 YES
• 22.06 ± 0.49 MPa Defective suction valve Repair or replace
{225 ± 5 kg/cm2} Is arm OUT relief
• Engine at high pressure
idling NO normal?
Defective central safety Replace
• 22.06 ± 0.49MPa NO valve
{225 ± 5 kg/cm2}
• Engine at high
idling

PC30MRX-1
Cause Remedy

4 YES
Defective arm cylinder Repair or replace
Does pressure packing
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or replace
YES Does control NO valve
valve spool
move smoothly?
2

YES Is output NO
Defective operation of Repair or replace
pressure of PPC control valve spool
valve normal?
1
• 2.94 +0.49
–0.1 MPa
{30 +5 2 Defective PPC valve Repair or replace
–1 kg/cm } NO
Is arm IN relief • Engine at high
pressure normal? idling
5 YES
• 25.5 ± 0.49 MPa Defective suction valve Repair or replace
{260 ± 5 kg/cm2} Is arm OUT relief
• Engine at high pressure
idling NO normal?
Defective central safety Replace
• 25.5 ± 0.49MPa NO valve
{260 ± 5 kg/cm2}
• Engine at high
idling

PC27 – 45MRX-1 20-417

TROUBLESHOOTING H-7

PC35, 40, 45MRX-1

Cause Remedy

4 YES
Defective arm cylinder Repair or replace
Does pressure packing
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or replace
YES Does control NO valve
valve spool
move smoothly?
2

YES Is output NO
Defective operation of Repair or replace
pressure of PPC control valve spool
valve normal?
1
• 2.94 +0.49
–0.1 MPa
{30 +5 2 Defective PPC valve Repair or replace
–1 kg/cm } NO
Is arm IN relief • Engine at high
pressure normal? idling
5 YES
• 26.3 ± 0.49MPa Defective suction valve Repair or replace
{268 ± 5 kg/cm2} Is arm OUT relief
• Engine at high pressure
idling NO normal?
Defective central safety Replace
• 26.3 ± 0.49MPa NO valve
{268 ± 5 kg/cm2}
• Engine at high
idling

20-418 PC27 – 45MRX-1

TROUBLESHOOTING H-8

H-8 Bucket is slow or lacks power

PC27MRX-1
Cause Remedy

4 YES
Defective bucket cylinder Repair or replace
Does pressure packing
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or replace
YES Does control NO valve
valve spool
move smoothly?
2

YES Is output NO
Defective operation of Repair or replace
pressure of PPC control valve spool
valve normal?
1
• 2.94 +0.49
–0.1 MPa
{30 +5 2 Defective PPC valve Repair or replace
–1 kg/cm } NO
Is bucket CURL • Engine at high
relief pressure
normal? idling
5 YES
• 22.06 ± 0.49 MPa Defective suction valve Repair or replace
{225 ± 5 kg/cm2} Is bucket DUMP
• Engine at high relief pressure
idling NO normal?
Defective central safety Replace
• 22.06 ± 0.49 MPa NO valve
{225 ± 5 kg/cm2}
• Engine at high
idling

PC30MRX-1

Cause Remedy

4 YES
Defective bucket cylinder Repair or replace
Does pressure packing
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or replace
YES Does control NO valve
valve spool
move smoothly?
2

YES Is output NO
Defective operation of Repair or replace
pressure of PPC control valve spool
valve normal?
1
• 2.94 +0.49
–0.1 MPa
{30 +5 2 Defective PPC valve Repair or replace
–1 kg/cm } NO
Is bucket CURL • Engine at high
relief pressure
normal? idling
5 YES
• 25.5 ± 0.49 MPa Defective suction valve Repair or replace
{260 ± 5 kg/cm2} Is bucket DUMP
• Engine at high relief pressure
idling NO normal?
Defective central safety Replace
• 25.5 ± 0.49 MPa NO valve
{260 ± 5 kg/cm2}
• Engine at high
idling

PC27 – 45MRX-1 20-419

TROUBLESHOOTING H-8

PC35, 40, 45MRX-1

Cause Remedy

4 YES
Defective bucket cylinder Repair or replace
Does pressure packing
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or replace
YES Does control NO valve
valve spool
move smoothly?
2

YES Is output NO
Defective operation of Repair or replace
pressure of PPC control valve spool
valve normal?
1
• 2.94 +0.49
–0.1 MPa
{30 +5 2 Defective PPC valve Repair or replace
–1 kg/cm } NO
Is bucket CURL • Engine at high
relief pressure
normal? idling
5 YES
• 26.3 ± 0.49 MPa Defective suction valve Repair or replace
{268 ± 5 kg/cm2} Is bucket DUMP
• Engine at high relief pressure
idling NO normal?
Defective central safety Replace
• 26.3 ± 0.49 MPa NO valve
{268 ± 5 kg/cm2}
• Engine at high
idling

20-420 PC27 – 45MRX-1

 TROUBLESHOOTING H-9

H-9 Boom swing is slow or lacks power

PC27MRX-1
Cause Remedy

Defective operation of
4 YES check valve inside control Repair or replace
YES valve spool
3 Is boom swing
cylinder leakage
Does pressure normal?
YES compensation Defective boom swing Repair or replace
valve move • 10 cc/min NO cylinder packing
smoothly ?
2
Defective operation of
pressure compensation Repair or replace
YES Is travel of NO valve
control pedal
normal?

• 25 ± 5 mm 5 YES Defective adjustment of

Adjust
control pedal linkage
1 Is stroke of
control valve
NO spool normal?
Is boom swing Defective operation of
relief pressure Repair or replace
NO control valve spool
normal? • 6 mm

• 22.06 ± 0.49 MPa

{225 ± 5 kg/cm2} 6 YES
Defective suction valve Repair or replace
• Engine at high
idling Is arm relief
pressure
NO normal?
Defective central safety Replace
• 22.06 ± 0.49 MPa NO valve
{225 ± 5 kg/cm2}
• Engine at high
idling

PC27 – 45MRX-1 20-421

TROUBLESHOOTING H-9

PC30MRX-1
Cause Remedy

Defective operation of
4 YES check valve inside control Repair or replace
valve spool
YES Is boom swing
cylinder leakage
3 normal?
Does pressure Defective boom swing Repair or replace
YES compensation • 10 cc/min NO cylinder packing
valve move
smoothly ?
2 Defective operation of
pressure compensation Repair or replace
YES Is travel of NO valve
control pedal
normal?
5 YES Defective adjustment of
• 25 ± 5 mm Adjust
control pedal linkage
1 Is stroke of
control valve
NO spool normal?
Is boom swing Defective operation of
relief pressure Repair or replace
normal? • 6 mm NO control valve spool

• 25.5 ± 0.49 MPa

{260 ± 5 kg/cm2} 6 YES Defective suction valve Repair or replace
• Engine at high
idling Is arm relief
pressure
NO normal?
Defective central safety Replace
• 25.5 ± 0.49 MPa NO valve
{260 ± 5 kg/cm2}
• Engine at high
idling

20-422 PC27 – 45MRX-1

TROUBLESHOOTING H-9

PC35, 40, 45MRX-1

Cause Remedy

Defective operation of
4 YES check valve inside control Repair or replace
YES Is boom swing valve spool
3 cylinder leakage
Does pressure normal?
YES compensation Defective boom swing Repair or replace
valve move • 10 cc/min NO cylinder packing
smoothly ?
2
Defective operation of
pressure compensation Repair or replace
YES Is travel of
control pedal
NO valve
normal?

• 25 ± 5 mm 5 YES Defective adjustment of Adjust

control pedal linkage
1 Is stroke of
control valve
Is boom swing NO spool normal?
relief pressure Defective operation of Repair or replace
normal? • 6 mm NO control valve spool

• 26.3 ± 0.49 MPa

{268 ± 5 kg/cm2} 6 YES
• Engine at high Defective suction valve Repair or replace
idling Is arm relief
pressure
NO normal?
Defective central safety Replace
• 26.3 ± 0.49 MPa NO valve
{268 ± 5 kg/cm2}
• Engine at high
idling

PC27 – 45MRX-1 20-423

TROUBLESHOOTING H-10

H-10 Blade is slow or lacks power Cause Remedy

PC27MRX-1
Defective operation of
YES pressure compensation Repair or replace
3 valve (inside boom swing
control valve)
YES Is boom swing
also slow? Defective operation of
4 YES check valve inside control Repair or replace
valve spool
Is blade cylinder
2 leakage normal?
NO
YES Is travel of Defective blade cylinder Repair or replace
control pedal • 10 cc/min NO packing
normal?

• 50 ± 5 mm 5 YES Defective adjustment of Adjust

1 control lever linkage
Is stroke of
control valve
Is blade LOWER NO spool normal?
relief pressure
normal? Defective operation of Repair or replace
• 6 mm NO control valve spool
• 21.57 ± 0.49 MPa
{220 ± 5 kg/cm2}
• Engine at high 6 YES
Defective suction valve Repair or replace
idling Does condition
become normal
when suction
NO valve is
replaced? Defective central safety
Replace
NO valve

Cause Remedy
PC30, 35, 40, 45MRX-1

Defective operation of
YES pressure compensation Repair or replace
3 valve (inside boom swing
control valve)
YES Is boom swing
also slow? Defective operation of
4 YES check valve inside control Repair or replace
valve spool
Is blade cylinder
2 leakage normal?
NO
YES Is travel of Defective blade cylinder Repair or replace
control pedal • 10 cc/min NO packing
normal?

• 50 ± 5 mm 5 YES Defective adjustment of Adjust

1 control lever linkage
Is stroke of
control valve
Is blade LOWER NO spool normal?
relief pressure
normal? Defective operation of Repair or replace
• 6 mm NO control valve spool
• 21.6 ± 0.49 MPa
{220 ± 5 kg/cm2}
• Engine at high 6 YES
Defective suction valve Repair or replace
idling Does condition
become normal
when suction
NO valve is
replaced? Defective central safety
Replace
NO valve

20-424 PC27 – 45MRX-1

TROUBLESHOOTING H-11

H-11 Boom, arm, bucket do not move (boom swing, blade, travel and
swing are normal)
PC27, 30, 35, 40, 45MRX-1
fl If the boom, arm, or bucket do not move when they are operated independently.

Cause Remedy

1 YES Defective operation of Repair or replace

control valve spool
Is output
pressure of PPC
valve normal?
Defective PPC valve Repair or replace
• 2.94 +0.49
–0.1 MPa NO
2
{30 +5
–1 kg/cm }
• Engine at high
idling

PC27 – 45MRX-1 20-425

TROUBLESHOOTING H-12

H-12 Excessive hydraulic drift (boom, arm, bucket, boom swing, blade)
PC27, 30, 35, 40, 45MRX-1
fl When there is simultaneous hydraulic drift in the boom, arm, bucket, and boom swing, judge that the
cause is a defective central safety valve.

a) Boom
Cause Remedy

2 YES
Defective suction valve Repair or replace
Does conditon
YES become normal
1 when suction
valve is replaced?
Defective oil tightness of
Is hydraulic Repair or replace
NO control valve spool
cylinder leakage
normal?

• 10 cc/min Defective cylinder piston Repair or replace

• Engine at high NO packing
idling

b) Arm, bucket, boom swing

Cause Remedy

2 One direction Defective suction valve Repair or replace

Is there hydraulic only
YES drift in one direc-
tion (extended or
1 retracted) or on
both directions? Defective oil tightness of Repair or replace
Is hydraulic Both directions
control valve spool
cylinder leakage
normal?

• 10 cc/min Defective cylinder piston

Repair or replace
• Engine at high NO packing
idling

c) Blade

Cause Remedy

1 YES Defective oil tightness of

control valve spool Repair or replace
Is hydraulic
cylinder leakage
normal?
Defective cylinder piston Repair or replace
• 10 cc/min NO packing
• Engine at high
idling

20-426 PC27 – 45MRX-1

TROUBLESHOOTING H-13, H-14

H-13 Excessive time lag (engine at low idling)

PC27, 30, 35, 40, 45MRX-1
fl When the work equipment speed is normal.
Cause Remedy

Defective suction valve Repair or replace

H-14 In compound operations, work equipment with larger load is slow

PC27, 30, 35, 40, 45MRX-1
Cause Remedy

Defective operation of
pressure compensation
Replace
valve on side where load
is light

Combination for compound Side with Side with

operation larger load lighter load

1 Boom RAISE + arm IN Boom RAISE Arm IN

2 Boom RAISE + arm OUT Arm OUT Boom RAISE

3 Boom RAISE + bucket CURL Boom RAISE Bucket CURL

4 Arm OUT + bucket CURL Arm OUT Bucket CURL

5 Boom LOWER + arm OUT Arm OUT Boom LOWER

PC27 – 45MRX-1 20-427

TROUBLESHOOTING H-15

H-15 Travel deviation

PC27, 30, 35, 40, 45MRX-1
a) When there is deviation during normal travel

Cause Remedy

YES Repair or replace

Defective final drive
3
Are metal parti-
YES cles in oil drained
from final drive
on side which de- 4 YES Repair or replace
Defective travel motor
viates? Does
2 counterbalance
Does pressure valve on side
YES compensation NO which deviates
valve on side move smoothly?
which deviates Defective counterbalance Repair or replace
move smoothly? NO valve

1
Is distance of Defective operation of
pressure compensation Repair or replace
movement of left
and right travel NO valve
control levers
normal?
5 YES Defective adjustment of
• 85 ± 10 mm travel control lever Adjust
linkage
Is stroke of
control valve
NO spool normal?
Defective operation of Repair or replace
• 6 mm NO control valve spool

b) There is deviation when machine moves off

Cause Remedy

Defective operation of
counterbalance valve Repair or replace

20-428 PC27 – 45MRX-1

 TROUBLESHOOTING H-15

PC30, 40, 45MRX-1

a) When there is deviation during normal travel

Cause Remedy

4 YES
Defective pump Replace
Does condition
YES become normal
when pump
assembly is
3 replaced? Go to Troubleshooting
NO Item No. 7
YES Is locknut of PC
valve loose?
5 YES Defective locking by
Direction of locknut Tighten
2 Does condition
deviation become normal
changes Is relief pressure when locknut of
NO PC valve is
at travel motor
tightened? Go to Troubleshooting
relief normal?
NO Item No. 4
• 26.3 ± 0.49 MPa
{268 ± 5 kg/cm2}
• Engine at full Drop in set pressure of
1 throttle Adjust or replace
When pump NO NO main relief valve
outlet hoses are
changed between
left and right, YES
does direction of Defective final drive Repair or replace
deviation 7
change?
Are metal
YES particles found in
oil drained from 8 YES
final drive on side Defective control valve Replace
Does direction of
6 which deviates? deviation change
when left and
Is stroke of right hoses
control valve NO between control
spool normal? valve and swivel
Direction of are interchanged?
deviation Go to A
does not • 6 mm NO
change Defective operation of
travel lever linkage Repair or replace
NO (cable) or defective
operation of control valve
spool

9 YES Replace packing

Defective swivel joint
Does direction of or replace ass y
deviation change
A when left and
right hoses
between swivel
and travel motor
are interchanged?
Defective travel motor Replace
NO

PC27 – 45MRX-1 20-429

TROUBLESHOOTING H-15

b) There is deviation when machine moves off

Cause Remedy

Defective operation of
counterbalance valve Repair or replace

c) Deviates in same direction in forward and reverse

Cause Remedy

2 YES Defective balance of See TESTING

discharge from main AND
pumps ADJUSTING
YES Is track tension
1 normal?
Is direction of Defective track shoe tension Adjust
deviation same in NO
forward and
reverse?

Go to H-15 a), b)
NO

20-430 PC27 – 45MRX-1

TROUBLESHOOTING H-16

H-16 Travel speed is slow or lacks power

PC27MRX-1
fl When there is no travel deviation (if there is travel deviation, go to H-15 Travel deviation).
fl When the work equipment speed is normal.
Cause Remedy

2 YES Defective adjustment of Adjust

PC valve
Does condition
YES become normal
when PC valve is
adjusted?
Defective PC valve, servo
1 Repair or replace
piston
NO
Is travel relief
pressure
normal? 3 YES Defective adjustment of
Adjust
main relief valve
• 22.09 ± 0.49 MPa Does condition
become normal
{225 ± 5 kg/cm2} when main relief
• Engine at high NO
valve is adjusted?
idling Defective main relief
Repair or replace
NO valve

PC30, 35, 40, 45MRX-1

fl When there is no travel deviation (if there is travel deviation, go to H-15 Travel deviation).
fl When the work equipment speed is normal.

Cause Remedy

2 YES Defective adjustment of Adjust

PC valve
Does condition
YES become normal
when PC valve is
adjusted?
Defective PC valve, servo
1 Repair or replace
piston
NO
Is travel relief
pressure
normal? 3 YES Defective adjustment of
Adjust
main relief valve
PC30MRX-1 Does condition
become normal
• 25.5 ± 0.49 MPa when main relief
{260 ± 5 kg/cm }
2 NO
valve is adjusted?
PC35,40,45MRX-1 Defective main relief
Repair or replace
valve
• 26.3 ± 0.49 MPa NO
{268 ± 5 kg/cm2}
• Engine at high
idling

PC27 – 45MRX-1 20-431

TROUBLESHOOTING H17, H-18, H-19

H-17 Steering does not turn easily

PC27, 30, 35, 40, 45MRX-1
fl When there is no travel deviation (if there is travel deviation, go to H-15 Travel deviation).

Cause Remedy

2 YES Defective center swivel Repair or replace

Does pressure joint
YES compensation
valve on inside of
1 steering move
smoothly? Defective operation of
Does control pressure compensation Repair or replace
NO valve
valve spool move
smoothly?

Defective operation of
control valve spool Repair or replace
NO

H-18 Travel speed does not switch

PC27, 30, 35, 40, 45MRX-1 Cause Remedy

1 YES Defective travel motor

speed selector servo Repair or replace
Is output
pressure of travel
boost solenoid
valve normal?
Defective travel boost Repair or replace
• Travel boost pedal NO solenoid valve
2
ON: 2.94 +0.49 +5
–0.1 MPa {30 –1 kg/cm }
• Travel boost pedal
OFF: 0 MPa {0 kg/cm2}
• Engine at high idling

H-19 Travel does not move (one side only)

PC27, 30, 35, 40, 45MRX-1 Cause Remedy

YES
Defective final drive Repair or replace
1
Is any foreign
material found in
oil drained from 2 YES
final drive? Defective travel motor Repair or replace
Does
counterbalance
NO valve move
smoothly? Defective counterbalance
valve Repair or replace
NO

20-432 PC27 – 45MRX-1

TROUBLESHOOTING H-20

H-20 Swing speed is slow or lacks power

PC27, 30MRX-1
a) Speed is slow or lacks power in both directions

Cause Remedy

YES
Defective swing motor Repair or replace
1

Is swing relief
pressure normal? YES Defective adjustment of
Adjust
2 swing motor safety valve
+0.49
• 18.0–0 MPa Does condition
{184 kg/cm2}
+5
–0 become normal
• Engine at high NO when safety 3 YES Defective swing motor
idling valve is adjusted? safety valve Replace
Does condition
become normal
NO when safety
valve is replaced?
Defective gear pump Repair or replace
NO

b) Speed is slow or lacks power in one direction only (left or right)

Cause Remedy

3 YES Defective swing motor Repair or replace

Does condition check valve
YES become normal
when swing
2 motor check
valve is replaced? Defective swing motor
suction valve Repair or replace
YES Does control NO
valve spool move
1 smoothly?

Is output Defective operation of

control valve spool Repair or replace
pressure of PPC NO
valve normal?

• 2.94 +0.49
–0.1 MPa
2 Defective PPC valve Repair or replace
{30 +5
–1 kg/cm }
• Engine at high NO
idling

PC27 – 45MRX-1 20-433

 TROUBLESHOOTING H-20

PC35, 40, 45MRX-1

a) Speed is slow or lacks power in both directions

Cause Remedy

YES
Defective swing motor Repair or replace
1

Is swing relief
pressure normal? YES Defective adjustment of
Adjust
2 swing motor safety valve
PC35MRX-1 Does condition
• 18.6 ± 0.98 MPa become normal
{190 ± 10 kg/cm } NO when safety
2
3 YES Defective swing motor
PC40,45MRX-1 valve is adjusted? safety valve Replace
• 21.0 ± 0.98 MPa Does condition
become normal
{215 ± 10 kg/cm2} when safety
• Engine at high NO
valve is replaced?
idling Defective gear pump Repair or replace
NO

b) Speed is slow or lacks power in one direction only (left or right)

Cause Remedy

3 YES Defective swing motor Repair or replace

Does condition check valve
YES become normal
when swing
2 motor check
valve is replaced? Defective swing motor
suction valve Repair or replace
YES Does control NO
valve spool move
1 smoothly?

Is output Defective operation of

control valve spool Repair or replace
pressure of PPC NO
valve normal?

• 2.94 +0.49
–0.1 MPa
2 Defective PPC valve Repair or replace
{30 +5
–1 kg/cm }
• Engine at high NO
idling

20-434 PC27 – 45MRX-1

TROUBLESHOOTING H-21

H-21 Does not swing

PC27, 30, 35, 40, 45MRX-1

a) Does not swing in either direction

Cause Remedy

2 YES Defective swing Repair or replace

Is any foreign machinery
YES material found in
oil drained from
1 swing
machinery? Defective swing motor or
Does oil come defective swing holding Repair or replace
out when gear NO brake
pump outlet hose
is disconnected?
• Crank engine by Defective gear pump Repair or replace
hand. NO

b) Does not swing in one direction (left or right)

Cause Remedy

2 YES Defective operation of

PPC shuttle valve inside Repair or replace
control valve
YES Does control
valve spool move
1 smoothly?
Defective operation of
Is output control valve spool Repair or replace
NO
pressure of PPC
valve normal?

• 2.94 +0.49
–0.1 MPa Defective PPC valve Repair or replace
2 NO
{30 +5
–1 kg/cm }
• Engine at high
idling

PC27 – 45MRX-1 20-435

 TROUBLESHOOTING H-22

H-22 Swing acceleration is poor

PC27, 30, 35, 40, 45MRX-1
a) Acceleration is poor in both directions

Cause Remedy

1 YES Defective swing motor

safety valve Repair or replace
Does condition
become normal
when swing
motor safety
valve is replaced? Defective swing motor or
defective swing holding Repair or replace
NO brake

b) Acceleration is poor in one direction only (left or right)

Cause Remedy

3 YES Defective swing motor Repair or replace

suction valve
Does PPC shuttle
YES valve inside
2 control valve
move smoothly? Defective operation of
PPC shuttle valve inside Repair or replace
YES Does control NO control valve
valve spool move
1 smoothly?

Is output Defective operation of

control valve spool Repair or replace
pressure of PPC NO
valve normal?

• 2.94 +0.49
–0.1 MPa
2 Defective PPC valve Repair or replace
{30 +5
–1 kg/cm }
• Engine at high NO
idling

20-436 PC27 – 45MRX-1

TROUBLESHOOTING H-23

H-23 Excessive overrun when stopping swing

PC27, 30, 35, 40, 45MRX-1
a) Overrun when stopping is excessive in both directions (left and right)
(When PPC circuit throttle, operation of control valve spool are normal)

Cause Remedy

Defective swing motor Repair or replace

b) Overrun when stopping is excessive in one direction only (left or right)

Cause Remedy

YES Defective swing PPC slow Clean or replace

return valve

1 YES Defective swing motor Repair or replace

3 suction valve
Is throttle of PPC Does condition
circuit clogged? YES become
when swing
normal

motor suction 4 YES Defective swing motor

check valve Repair or replace
valve is replaced? Does condition
2 become normal
when swing
Does control NO motor check
valve spool valve is replaced?
NO move smoothly? Defective PPC valve Repair or replace
NO

Defective operation of Repair or replace

NO control valve spool

PC27 – 45MRX-1 20-437

TROUBLESHOOTING H-24, H-25, H-26

H-24 Excessive shock when stopping swing (in one direction only)
PC27, 30, 35, 40, 45MRX-1
Cause Remedy

1 YES
Defective PPC valve Repair or replace
Does control
valve spool move
smoothly?
Defective operation of Repair or replace
NO control valve spool

H-25 Excessive abnormal noise when stopping swing

PC27, 30, 35, 40, 45MRX-1

Cause Remedy

YES Defective swing motor

safety valve Replace
1
Does condition
become normal
when safety YES Defective swing motor
valve is replaced? Clean
2 suction valve
Does condition
become normal
NO when suction 3 YES Defective swing
valve is cleaned? machinery Repair or replace
Is foreign
material found in
oil drained from
NO swing
machinery? Defective control valve
cooler check valve Repair or replace
NO

H-26 Excessive hydraulic drift of swing

PC27, 30, 35, 40, 45MRX-1
Cause Remedy

Defective swing holding

brake Repair or replace

20-438 PC27 – 45MRX-1

TROUBLESHOOTING

TROUBLESHOOTING OF
MACHINE MONITOR SYSTEM
(M MODE)

M mode related electrical circuit deagram ........................................................................................... 20-503

M- 1 When starting switch is turned ON, no display is given ........................................................... 20-506
M- 2 When starting switch is turned ON, even when self check is completed
(all lamps light up for 3 seconds), lamps do not go out ........................................................... 20-508
M- 3 When starting switch is turned ON, some self check lamps do not light up for 3 seconds ... 20-509
a) No gauge lamps light up (fuel, coolant temperature) .......................................................... 20-509
b) Caution lamps (engine oil pressure, battery charge), pilot lamp (preheating)
do not light up ......................................................................................................................... 20-509
M- 4 During self check (all lamps light up for 3 seconds), even if starting switch is turned
to START, self check is not completed for 3 seconds ................................................................ 20-509
M- 5 When starting switch is ON (engine stopped), engine oil pressure caution lamp does not
light up .......................................................................................................................................... 20-510
M- 6 When starting switch is ON (engine stopped), charge caution lamp does not light up ......... 20-511
M- 7 When starting switch is turned to HEAT, preheating pilot lamp does not light up ................. 20-512
M- 8 When engine is running, engine oil pressure caution lamp lights up ..................................... 20-513
M- 9 When engine is running, charge caution lamp lights up .......................................................... 20-514
M-10 Abnormality in coolant temperature gauge ............................................................................... 20-515
a) Level does not rise from segment C ...................................................................................... 20-515
b) Level does not go down from segment H, or all segments go out .................................... 20-515
c) Coolant temperature does not match gauge display ........................................................... 20-516
M-11 Abnormality in fuel gauge ........................................................................................................... 20-519
a) Level does not rise from segment E or all segments go out ............................................... 20-519
b) Level does not go down from segment F ............................................................................. 20-519
c) Fuel level does not match gauge display .............................................................................. 20-520
M-12 Defective operation of alarm buzzer ........................................................................................... 20-523
a) Buzzer does not sound ........................................................................................................... 20-523
b) Buzzer continues to sound and does not stop ...................................................................... 20-523
M-13 When engine is running, service meter does not advance....................................................... 20-526
a) When charge caution lamp does not light up ...................................................................... 20-526
b) When charge caution lamp lights up .................................................................................... 20-526
c) Pilot lamp does not flash (service meter is actuated) .......................................................... 20-526
M-14 Night lighting does not light up .................................................................................................. 20-527
a) Gauge lighting does not light up ........................................................................................... 20-527
b) Service meter lighting does not light up ............................................................................... 20-527

PC27 – 45MRX-1 20-501

TROUBLESHOOTING

20-502 PC27 – 45MRX-1

TROUBLESHOOTING M-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

M-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

PC27, 30MRX-1

PC27 – 45MRX-1 20-503

TROUBLESHOOTING M-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

PC35MRX-1

20-504 PC27 – 45MRX-1

TROUBLESHOOTING M-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

PC40, 45MRX-1

PC27 – 45MRX-1 20-505

TROUBLESHOOTING M-1

M-1 When starting switch is turned ON, no display is given

PC27, 30MRX-1
fl Check that fuse 3 is normal (if it is blown, check for a short circuit with the ground in the circuits
related to fuse 3).
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

2 YES Replace
Defective monitor panel
Is resistance
between P1 Defective contact or
YES (female) (3)(4)
and chassis disconnection in wiring
ground normal? harness between P1
1 (female) (3)(4) – M9 (3) – Repair or replace
• Max. 1 Ω NO T10 – chassis ground
Is voltage • Turn starting
between P1 (1) switch OFF. Defective contact or
and chassis • Disconnect P1. disconnection in wiring
ground normal? 3 YES
harness between starting Repair or replace
Is voltage switch terminal ACC –
• 10 – 14 V between starting
• Turn starting switch terminal M29 (2) – fuse 3 – M 30 (3)
switch ON. NO ACC and chassis – P1 (female) (1)
ground normal?
Defective starting switch Replace
• 10 – 14 V NO
• Turn starting
switch ON.

M-1 Related electrical circuit diagram

20-506 PC27 – 45MRX-1

TROUBLESHOOTING M-1

PC35MRX-1
Cause Remedy

2 YES Replace
Defective monitor panel
Is resistance
between P1 Defective contact or
YES (female) (3)(4)
and chassis disconnection in wiring
ground normal? harness between P1
1 (female) (3)(4) – M9 (3) – Repair or replace
• Max. 1 Ω NO T10 – chassis ground
Is voltage • Turn starting
between P1 (1) switch OFF. Defective contact or
and chassis • Disconnect P1. disconnection in wiring
ground normal? 3 YES
harness between Repair or replace
Is voltage starting switch terminal
• 10 – 14 V between starting
• Turn starting switch terminal ACC – fuse 3 – P1
switch ON. NO ACC and chassis (female) (1)
ground normal?
Defective starting switch Replace
• 10 – 14 V NO
• Turn starting
switch ON.

M-1 Related electrical circuit diagram

PC27 – 45MRX-1 20-507

TROUBLESHOOTING M-1, M-2

PC40, 45MRX-1
Cause Remedy

2 YES Replace
Defective monitor panel
Is resistance
between P1 Defective contact or
YES (female) (3)(4)
disconnection in wiring
and chassis harness between P1
ground normal? (female) (3)(4) – M56 (1) –
1 Repair or replace
• Max. 1 Ω NO M5 (2) – T12 – chassis
Is voltage • Turn starting ground
between P1 (1) switch OFF.
and chassis • Disconnect P1. Defective contact or
ground normal? 3 YES disconnection in wiring
harness between starting Repair or replace
Is voltage
• 10 – 14 V between starting switch terminal ACC – M55
• Turn starting switch terminal (3) – M41 (1) – fuse 3 – M 40
switch ON. NO ACC and chassis (2) – M55 (2) – P1 (female) (1)
ground normal?
Defective starting switch Replace
• 10 – 14 V
NO
• Turn starting
switch ON.

M-1 Related electrical circuit diagram

M-2 When starting switch is turned ON, even when self check is com-
pleted (all lamps light up for 3 seconds), lamps do not go out
PC27, 30, 35, 40, 45MRX-1
Cause Remedy

Defective monitor panel Replace

20-508 PC27 – 45MRX-1

TROUBLESHOOTING M-3, M-4

M-3 When starting switch is turned ON, some self check lamps do not
light up for 3 seconds
PC27, 30, 35, 40, 45MRX-1
a) No gauge lamps light up (fuel, coolant temperature)
Cause Remedy

Defective monitor panel Replace

b) Caution lamps (engine oil pressure, battery charge), pilot lamp (preheating) do not light up

Cause Remedy

1 YES
Blown bulb Replace
Is there
disconnection in
lamp which does
not light up?
Defective monitor panel Replace
• Check visually for NO
blown bulb.

M-4 During self check (all lamps light up for 3 seconds), even if starting
switch is turned to START, self check is not completed for 3 sec-
onds
PC27, 30, 35, 40, 45MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

Cause Remedy

1 YES
Defective monitor panel Replace
Is voltage
between P1 (5)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between starting Repair or replace
• Turn starting NO switch terminal C and P1
switch to START. (female) (5)
• 10 – 14 V

M-4 Related electrical circuit diagram

PC27 – 45MRX-1 20-509

TROUBLESHOOTING M-5

M-5 When starting switch is ON (engine stopped), engine oil pressure

caution lamp does not light up
PC27, 30, 35MRX-1
fl Before carrying out troubleshooting, check that all the related Cause Remedy
connectors are properly inserted.
fl Always connect any disconnected connectors before going on
the next step. 2 YES
Defective monitor panel Replace
Is Is resistance
YES between P1
(female) (9) and
1 chassis ground Defective contact or
Is resistance normal? disconnection in wiring
between T5 harness between P1 Repair or replace
• Max. 1 Ω NO (female) (9) – M9 (6) – T5
(terminal switch) • Turn starting
and chassis (female)
ground normal? switch OFF.
• Disconnect P1.
• Max. 1 Ω Defective engine oil
Replace
• Turn starting NO pressure switch
switch OFF.
• Disconnect T5.

M-5 Related electrical circuit diagram

PC40, 45MRX-1
Cause Remedy

2 YES
Defective monitor panel Replace
Is Is resistance
YES between P1
(female) (9) and
1 chassis ground Defective contact or
Is resistance normal? disconnection in wiring
between M42 harness between P1 Repair or replace
• Max. 1 Ω NO (female) (9) – M54 (1) –
(terminal switch) • Turn starting
and chassis M4 (2) – M42
ground normal? switch OFF.
• Disconnect P1.
• Max. 1 Ω Defective engine oil
Replace
• Turn starting NO pressure switch
switch OFF.
• Disconnect M42.

M-5 Related electrical circuit diagram

20-510 PC27 – 45MRX-1

 TROUBLESHOOTING M-6

M-6 When starting switch is ON (engine stopped), charge caution lamp

does not light up
PC27, 30, 35MRX-1
Cause Remedy
fl Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
fl Always connect any disconnected connectors before going on
the next step. 2 YES
Defective monitor panel Replace
Is voltage
YES between P1 (10)
1 and chassis
ground normal? Short circuit with power
Is voltage source in wiring harness
between E1 Repair or replace
• Max. 5 V NO between P1 (female) (10)
(male) (1) and • Turn starting – M9 (7) – E1 (female) (1)
chassis ground
normal? switch ON.
• Max. 5 V Defective alternator Replace
• Disconnect E1 NO
• Turn starting
switch ON.

M-6 Related electrical circuit diagram

PC40, 45MRX-1 Cause Remedy

2 YES
Defective monitor panel Replace
Is voltage
YES between P1 (10)
1 and chassis
ground normal? Short circuit with power
Is voltage source in wiring harness
between M9 Repair or replace
• Max. 5 V NO between P1 (female) (10)
(male) (1) and • Turn starting – M54 (10) – M4 (5) –M9
chassis ground (female) (1)
normal? switch ON.
• Max. 5 V Defective alternator Replace
• Disconnect M9 NO
• Turn starting
switch ON.

M-6 Related electrical circuit diagram

PC27 – 45MRX-1 20-511

TROUBLESHOOTING M-7

M-7 When starting switch is turned to HEAT, preheating pilot lamp does
not light up
PC27, 30, 35MRX-1
fl When the engine preheating is normal.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.
Cause Remedy

1 YES
Defective monitor panel Replace
Is voltage
between P1 (13)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between P1 Repair or replace
• 10 – 14 V NO (female) (13) – starting
• Turn starting switch terminal R2 and R1
switch to HEAT.

M-7 Related electrical circuit diagram

PC40, 45MRX-1
Cause Remedy

1 YES
Defective monitor panel Replace
Is voltage
between P1 (13)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between P1 Repair or replace
• 10 – 14 V NO (female) (13) – starting
• Turn starting switch terminal R2 and R1
switch to HEAT.

M-7 Related electrical circuit diagram

20-512 PC27 – 45MRX-1

TROUBLESHOOTING M-8

M-8 When engine is running, engine oil pressure caution lamp lights up
PC27, 30, 35MRX-1
fl When the engine oil pressure is normal.
fl Before carrying out troubleshooting, check that all the related Cause Remedy
connectors are properly inserted.
fl Always connect any disconnected connectors before going on
the next step.
YES Defective engine oil
pressure switch Replace
1

Does lamp go out

when T5 is
disconnected? 2 YES Defective monitor panel Replace
Is resistance
• Start engine. between P1 (female)
(9) and chassis
NO ground normal Short circuit with chassis
when T5 is discon- ground in wiring harness Repair or replace
• Min. 1 MΩ NO between P1 (female) (9) –
• Turn starting M9 (6) – T5
switch OFF.
• Disconnect P1.

M-8 Related electrical circuit diagram

PC40,45MRX-1 Cause Remedy

YES Defective engine oil

pressure switch Replace
1

Does lamp go out

when M42 is
disconnected? 2 YES Defective monitor panel Replace
Is resistance
• Start engine. between P1 (female)
(9) and chassis
NO ground normal Short circuit with chassis
when M42 is dis- ground in wiring harness Repair or replace
• Min. 1 MΩ NO between P1 (female) (9) –
• Turn starting M54 (1) – M4 (2) – M42
switch OFF.
• Disconnect P1.

M-8 Related electrical circuit diagram

PC27 – 45MRX-1 20-513

 TROUBLESHOOTING M-9

M-9 When engine is running, charge caution lamp lights up

PC27, 30, 35MRX-1
fl When the charging is normal.
fl Before carrying out troubleshooting, check that all the related Cause Remedy
connectors are properly inserted.
fl Always connect any disconnected connectors before going on
the next step.
2 YES
Defective monitor panel Replace
Is voltage
YES between P1 (10)
and chassis Defective contact,
1 disconnection, or short
ground normal?
Is voltage circuit with chassis Repair or replace
between E1 (1) • 10 – 14 V NO ground in wiring harness
and chassis • Start engine. between P1 (female) (10)
ground normal? – M9 (7) – E1 (female) (1)

• 10 – 14 V Defective alternator Replace

• Start engine. NO

M-9 Related electrical circuit diagram

PC40, 45MRX-1
Cause Remedy

2 YES
Defective monitor panel Replace
Is voltage
YES between P1 (10)
Defective contact,
1 and chassis disconnection, or short
ground normal? circuit with chassis
Is voltage ground in wiring harness Repair or replace
between M9 (1) • 10 – 14 V NO
between P1 (female) (10)
and chassis • Start engine. – M54 (10) – M4 (5) – M9
ground normal? (female) (1)
• 10 – 14 V Defective alternator Replace
• Start engine. NO

M-9 Related electrical circuit diagram

20-514 PC27 – 45MRX-1

TROUBLESHOOTING M-10

M-10 Abnormality in coolant temperature gauge

PC27, 30, 35MRX-1
fl When the coolant temperature is normal.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

a) Level does not rise from segment C

Cause Remedy

YES Defective coolant

Replace
temperature sensor

1 Defective contact or
Does level go up 3 YES disconnection in wiring
one at a time and harness between P1 Repair or replace
finally do all seg- When P1 (6) is (female) (6) – M9 (4) – E7
ments go out YES connected to (female) (1)
when short con- chassis ground,
2 is condition same
nector is connect-
ed to E7 (female)? Is resistance as in Item 1?
between E7 Defective monitor panel Replace
• Turn starting NO
• Disconnect E7. (female) (2) and
NO chassis ground switch OFF.
• Turn starting
switch ON. normal? Defective contact or
disconnection in wiring
• Max. 1 Ω Repair or replace
harness between E7
• Turn starting NO (female) (2) and chassis
switch OFF.
ground
• Disconnect E7.

b) Level does not go down from segment H, or all segments go out

Cause Remedy

YES Defective coolant

temperature sensor Replace
1
Does level go
down one by one
when E7 is 2 YES Defective monitor panel Replace
disconnected? Is resistance
between P1 (fe-
• Turn starting male) (6) and
switch ON.
NO chassis ground Short circuit with chassis
normal when E7
is disconnected? ground in wiring harness
between P1 (female) (6) – Repair or replace
• Min. 1 MΩ NO M9 (4) – E7 (female) (1)
• Turn starting
switch OFF.
• Disconnect P1.

PC27 – 45MRX-1 20-515

TROUBLESHOOTING M-10

c) Coolant temperature does not match gauge display

Cause Remedy

1 YES
Defective monitor panel Replace
Is resistance
between E7
(male) (1) and (2)
as shown in the
table? Defective coolant
Replace
• Check sensor as NO temperature sensor
individual part.

Table
Temperature Resistance value Temperature Resistance value

25°C 38.18 – 47.77 90°C 4.469 – 5.166

30°C 31.59 – 39.07 95°C 4.107 – 4.448

80°C 6.199 – 6.935 100°C 3.604 – 3.903

85°C 5.386 – 5.976 105°C 3.157 – 3.426

M-10 Related electrical circuit diagram

20-516 PC27 – 45MRX-1

TROUBLESHOOTING M-10

PC40, 45MRX-1
fl When the coolant temperature is normal.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

a) Level does not rise from segment C

Cause Remedy

YES Defective coolant

Replace
temperature sensor

1 Defective contact or
Does level go up 3 YES disconnection in wiring
one at a time and harness between P1 Repair or replace
finally do all seg- When P1 (6) is (female) (6) – M54 (9) –
ments go out YES connected to M4 (1) – P2 (female) (1)
when short con- chassis ground,
2 is condition same
nector is connect-
ed to P2 (female)? Is resistance as in Item 1?
between P2 Defective monitor panel Replace
• Turn starting NO
• Disconnect P2. (female) (2) and
NO chassis ground switch OFF.
• Turn starting
switch ON. normal? Defective contact or
disconnection in wiring
• Max. 1 Ω Repair or replace
harness between P2
• Turn starting NO (female) (2) and chassis
switch OFF.
ground
• Disconnect P2.

b) Level does not go down from segment H, or all segments go out

Cause Remedy

YES Defective coolant

temperature sensor Replace
1
Does level go
down one by one
when P2 is 2 YES Defective monitor panel Replace
disconnected? Is resistance
between P1 (fe-
• Turn starting male) (6) and
switch ON. chassis ground Short circuit with chassis
NO normal when P2 ground in wiring harness
is disconnected? Repair or replace
between P1 (female) (6) –
• Min. 1 MΩ NO M54 (9) – M4 (1) – P2
• Turn starting (female) (1)
switch OFF.
• Disconnect P1.

PC27 – 45MRX-1 20-517

TROUBLESHOOTING M-10

c) Coolant temperature does not match gauge display

Cause Remedy

1 YES
Defective monitor panel Replace
Is resistance
between P2
(male) (1) and (2)
as shown in the
table? Defective coolant
Replace
• Check sensor as NO temperature sensor
individual part.

Table
Temperature Resistance value Temperature Resistance value

25°C 38.18 – 47.77 90°C 4.469 – 5.166

30°C 31.59 – 39.07 95°C 4.107 – 4.448

80°C 6.199 – 6.935 100°C 3.604 – 3.903

85°C 5.386 – 5.976 105°C 3.157 – 3.426

M-10 Related electrical circuit diagram

20-518 PC27 – 45MRX-1

TROUBLESHOOTING M-11

M-11 Abnormality in fuel gauge

PC27, 30, 35MRX-1
fl When the fuel level is normal.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

a) Level does not rise from segment E or all segments go out

Cause Remedy

YES
Defective fuel level sensor Replace

1 Defective contact or
Does level go up disconnection in wiring
one at a time 3 YES
harness between P1 Repair or replace
when M21 Is condition same (female) (7) – M9 (5) –
(female) (1), (2) YES as in Item 1 when M21 (female)
are connected? P1 (7) is
2 connected to
• Turn starting Is resistance chassis ground?
switch ON. between M21 Defective monitor panel Replace
• Turn starting NO
(male) (2) and switch ON.
NO chassis ground
normal? Defective contact or
• Max. 1 Ω disconnection in wiring
harness between M21 Repair or replace
• Turn starting NO
switch OFF. (female)(2) – T10 – chassis
• Disconnect M21. ground

b) Level does not go down from segment F

Cause Remedy

YES
Defective fuel level sensor Replace
1
Does level go
down one at a
time and finally do 2 YES
all segments go Defective monitor panel Replace
out when M21 is Is resistance
disconnected? between P1 (fe-
male) (7) and
• Turn starting chassis ground
switch ON. NO normal when M21 Short circuit with chassis
is disconnected? ground in wiring harness Repair or replace
• Min. 1 MΩ NO between P1 (female) (7) –
• Turn starting M9 (5) – M21 (female) (1)
switch OFF.
• Disconnect P1.

PC27 – 45MRX-1 20-519

TROUBLESHOOTING M-11

c) Fuel level does not match gauge display

Cause Remedy

1 YES
Defective monitor panel Replace
Is resistance
between M21
(male) (1), (2) and
shown in the
table?
Defective fuel level sensor Replace
• Check sensor as NO
individual part.

(Ω )
Float position Resistance value

Top 10 +1.0
–0.5

Top 1/4 (19)

1/2 (center) 32 ±3

Bottom 1/4 (49.5)

Bottom 80 +12
– 2

fl Figures in ( ) are reference values.

M-11 Related electrical circuit diagram

20-520 PC27 – 45MRX-1

TROUBLESHOOTING M-11

PC40, 45MRX-1
a) Level does not rise from segment E or all segments go out

Cause Remedy

YES
Defective fuel level sensor Replace

1 Defective contact or
Does level go up disconnection in wiring
one at a time 3 YES
harness between P1 Repair or replace
when M42 Is condition same (female) (7) – M54 (8) –
(female) (1), (2) YES as in Item 1 when M42 (female) (2)
are connected? P1 (7) is
2 connected to
• Connect short Is resistance chassis ground?
connector M42 between M42 Defective monitor panel Replace
(female) • Turn starting NO
(male) (2) and switch ON.
• Turn starting NO chassis ground
switch ON. normal? Defective contact or
• Max. 1 Ω disconnection in wiring
harness between M42 Repair or replace
• Turn starting NO
switch OFF. (female) (1) – M5 (2) – T12
• Disconnect M42. – chassis ground

b) Level does not go down from segment F

Cause Remedy

YES
Defective fuel level sensor Replace
1
Does level go
down one at a
time and finally do 2 YES
all segments go Defective monitor panel Replace
out when M42 is Is resistance
disconnected? between P1 (fe-
male) (7) and
• Turn starting NO chassis ground
normal when M42 Short circuit with chassis
switch ON. ground in wiring harness
is disconnected?
between P1 (female) (7) – Repair or replace
• Min. 1 MΩ NO M54 (8) – M42 (female)
• Turn starting (2)
switch OFF.
• Disconnect P1.

PC27 – 45MRX-1 20-521

 TROUBLESHOOTING M-11

c) Fuel level does not match gauge display

Cause Remedy

1 YES
Defective monitor panel Replace
Is resistance
between M42
(male) (1), (2) and
shown in the
table?
Defective fuel level sensor Replace
• Check sensor as NO
individual part.

(Ω )
Float position Resistance value

Top 10 +1.0
–0.5

Top 1/4 (19)

1/2 (center) 32 ±3

Bottom 1/4 (49.5)

Bottom 80 +12
+ 2

fl Figures in ( ) are reference values.

M-11 Related electrical circuit diagram

20-522 PC27 – 45MRX-1

TROUBLESHOOTING M-12

M-12 Defective operation of alarm buzzer

PC27, 30MRX-1
fl Check that fuse 4 is normal (if it is blown, check for a short circuit with the ground in the circuits
related to fuse 4).
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

a) Buzzer does not sound Cause Remedy

YES
Defective monitor panel Replace

1 Defective contact or
Does buzzer disconnection in wiring
sound when P1 3 YES
harness between P1 Repair or replace
(female) (15) and Does buzzer (female) (15) and P5
chassis ground YES sound when P5 (female) (1)
are connected? (1) and chassis
2 ground are
• Disconnect P1. connected?
• Turn starting Is voltage Defective buzzer Replace
switch ON. between P5 (2) • Turn starting NO
NO and chassis switch ON.
ground normal? Defective contact or
disconnection in wiring
• 10 – 14 V Repair or replace
harness between fuse 5 –
• Turn starting NO M30 (female) (5) – P5
switch ON.
(female) (2)

b) Buzzer continues to sound and does not stop

Cause Remedy

1 YES
Defective monitor panel Replace
Does buzzer stop
when P1 is
disconnected? Short circuit with chassis
ground in wiring harness
Repair or replace
• Turn starting NO between P1 (female) (15)
switch ON. and P5 (female) (1)

M-12Related electrical circuit diagram

PC27 – 45MRX-1 20-523

TROUBLESHOOTING M-12

PC35MRX-1
a) Buzzer does not sound

Cause Remedy

YES
Defective monitor panel Replace

1 Defective contact or
Does buzzer disconnection in wiring
sound when P1 3 YES
harness between P1 Repair or replace
(female) (15) and Does buzzer (female) (15) and P5
chassis ground YES sound when P5 (female) (1)
are connected? (1) and chassis
2 ground are
• Disconnect P1. connected?
• Turn starting Is voltage Defective buzzer Replace
switch ON. between P5 (2) • Turn starting NO
NO and chassis switch ON.
ground normal?
Defective contact or
• 10 – 14 V disconnection in wiring Repair or replace
• Disconnect P5 NO harness between fuse 5
• Turn starting and P5 (female) (2)
switch ON.

b) Buzzer continues to sound and does not stop

Cause Remedy

1 YES
Defective monitor panel Replace
Does buzzer stop
when P1 is
disconnected? Short circuit with chassis
ground in wiring harness
Repair or replace
• Turn starting NO between P1 (female) (15)
switch ON. and P5 (female) (1)

M-12 Related electrical circuit diagram

20-524 PC27 – 45MRX-1

TROUBLESHOOTING M-12

PC40, 45MRX-1
a) Buzzer does not sound

Cause Remedy

YES
Defective monitor panel Replace

1 Defective contact or
Does buzzer disconnection in wiring
sound when P1 3 YES
harness between P1 Repair or replace
(female) (15) and Does buzzer (female) (15) and M3
chassis ground YES sound when M3 (female) (1)
are connected? (1) and chassis
2 ground are
• Disconnect P1. Is voltage connected?
• Turn starting between M3 Defective buzzer Replace
switch ON. • Turn starting NO
(female)(2) and switch ON.
NO chassis ground
normal? Defective contact or
disconnection in wiring
• 10 – 14 V Repair or replace
harness between fuse 4 –
• Disconnect M3. NO M40 (3) – M3 (female) (2)
• Turn starting
switch ON.

b) Buzzer continues to sound and does not stop

Cause Remedy

1 YES
Defective monitor panel Replace
Does buzzer stop
when P1 is
disconnected? Short circuit with chassis
ground in wiring harness
Repair or replace
• Turn starting NO between P1 (female) (15)
switch ON. and M3 (female) (1)

M-12 Related electrical circuit diagram

PC27 – 45MRX-1 20-525

TROUBLESHOOTING M-13

M-13 When engine is running, service meter does not advance

PC27, 30, 35, 40, 45MRX-1
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

a) When charge caution lamp does not light up

Cause Remedy

Defective monitor panel Replace

b) When charge caution lamp lights up

fl Go to Troubleshooting No. M-9.

c) Pilot lamp does not flash (service meter is actuated)

Cause Remedy

Defective monitor panel Replace

20-526 PC27 – 45MRX-1

TROUBLESHOOTING M-14

M-14 Night lighting does not light up

PC27, 30MRX-1
fl Check that fuse 5 is normal (if it is blown, check for a short circuit with the ground in the circuits
related to fuse 5).
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on the next step.

a) Gauge lighting does not light up

Cause Remedy

YES Bulb of night lighting

(inside monitor panel) Replace
1 blown
Is voltage
between P1 (16) Defective contact or
and chassis YES disconnection in wiring
ground normal? harness between P1 Repair or replace
2 (female) (16) and P8
• 10 – 14 V Is voltage (female) (3)
• Turn starting between P8 (3)
switch ON.
NO and chassis 3 YES
Defective light switch Replace
• Turn light switch ground normal?
to 1. Is voltage
• 10 – 14 V between P8 (4)
• Turn starting NO and chassis Defective contact or
switch ON. ground normal?
disconnection in wiring
• Turn light switch Repair or replace
• 10 – 14 V NO harness between fuse 5 –
to 1. M30 (5) – P8 (female) (4)
• Turn starting
switch ON.

b) Service meter lighting does not light up

Cause Remedy

Defective monitor panel Replace

M-14 Related electrical circuit diagram

PC27 – 45MRX-1 20-527

TROUBLESHOOTING M-14

PC35MRX-1
a) Gauge lighting does not light up

Cause Remedy

YES Bulb of night lighting

(inside monitor panel) Replace
1 blown
Is voltage
between P1 (16) Defective contact or
and chassis YES disconnection in wiring
ground normal? harness between P1 Repair or replace
2 (female) (16) and P8
• 10 – 14 V Is voltage (female) (3)
• Turn starting between P8 (3)
switch ON.
NO and chassis 3 YES
Defective light switch Replace
• Turn light switch ground normal?
to 1. Is voltage
• 10 – 14 V between P8 (4)
• Turn starting NO and chassis Defective contact or
switch ON. ground normal?
disconnection in wiring
• Turn light switch Repair or replace
• 10 – 14 V NO harness between fuse 5
to 1. and P8 (female) (4)
• Turn starting
switch ON.

b) Service meter lighting does not light up

Cause Remedy

Defective monitor panel Replace

M-14 Related electrical circuit diagram

20-528 PC27 – 45MRX-1

TROUBLESHOOTING M-14

PC40, 45MRX-1
a) Gauge lighting does not light up

Cause Remedy

YES Bulb of night lighting

(inside monitor panel) Replace
1 blown
Is voltage
between P1 (16) Defective contact or
and chassis YES disconnection in wiring
ground normal? harness between P1 Repair or replace
2 (female) (16) – M54 (6) –
• 10 – 14 V Is voltage S6 (female) (3)
• Turn starting between S6 (3)
switch ON.
NO and chassis 3 YES
Defective light switch Replace
• Turn light switch ground normal?
to 1. Is voltage
• 10 – 14 V between S6 (4)
• Turn starting NO and chassis Defective contact or
switch ON. ground normal?
disconnection in wiring
• Turn light switch Repair or replace
• 10 – 14 V NO harness between fuse 4 –
to 1. M40 (3) – S6 (female) (4)
• Turn starting
switch ON.

b) Service meter lighting does not light up

Cause Remedy

Defective monitor panel Replace

M-14 Related electrical circuit diagram

PC27 – 45MRX-1 20-529

 30 DISASSEMBLY AND ASSEMBLY

Method of using manual ............................... 30-3 SWING MOTOR, SWING MACHINERY

Precautions when carrying out operation ... 30-4 Removal and Installation .......................... .30-53
SPECIAL TOOL LIST ...................................... 30-7 Disassembly .............................................. .30-58
SKETCHES OF SPECIAL TOOLS ................... 30-9 Assembly ................................................... .30-61
STARTING MOTOR SWING MOTOR
Removal and Installation .......................... .30-10 Disassembly ........................................... 30-63-I
ALTERNATOR Assembly ................................................ 30-63-6
Removal and Installation ........................ .,.30-l 2 REVOLVING FRAME
FUEL INJECTION PUMP Removal ..................................................... .30-64
Removal ..................................................... .30-l 5 Installation ................................................. .30-65
Installation ................................................. .30-l 6 SWING CIRCLE
NOZZLE HOLDER Removal and Installation .......................... .30-68
Removal and Installation .......................... .30-18 IDLER
WATER PUMP Removal and Installation .......................... .30-69
Removal and Installation .......................... .30-21 Disassembly .............................................. .30-70
THERMOSTAT Assembly ................................................... .30-71
Removal and Installation .......................... .30-22 RECOIL SPRING
ENGINE FRONT SEAL Removal and Installation .......................... .30-72
Removal and Installation .......................... .30-23 Disassembly .............................................. .30-73
ENGINE REAR SEAL Assembly ................................................... .30-75
Removal ..................................................... .30-24 TRACK ROLLER
Installation ................................................. .30-25 Removal and Installation .......................... .30-77
CYLINDER HEAD Disassembly .............................................. .30-78
Removal ..................................................... .30-26 Assembly ................................................... .30-79
Installation ................................................. .30-28 CARRIER ROLLER
RADIATOR, HYDRAULIC COOLER Removal and Installation .......................... .30-80
Removal ..................................................... .30-29 Disassembly and Assembly ..................... .30-81
Installation ................................................. .30-30 RUBBER SHOE
ENGINE, MAIN PUMP Removal and Installation .......................... .30-82
Removal ..................................................... .30-34 HYDRAULIC TANK
Installation ................................................. .30-37 Removal and Installation .......................... .30-83
DAMPER FUEL TANK
Removal and Installation .......................... .30-42 Removal ..................................................... .30-88
CENTER SWIVEL JOINT Installation ................................................. .30-89
Removal and Installation .......................... .30-43 MAIN PUMP
Disassembly and Assembly ..................... .30-47 Removal and Installation .......................... .30-91
TRAVEL MOTOR LPV30 (FOR PC30MRX-1)
Removal and Installation .......................... .30-51 Disassembly ........................................... 30-91-I
PHV-500 (FOR PC40MRX-1) Assembly ................................................ 30-91-9
Disassembly and assembly ................... 30-51-I LPD25+25 (FOR PC40MRX-1)
SPROCKET Disassembly ......................................... 30-91-20
Removal and Installation .......................... .30-52 Assembly .............................................. 30-91-29

PC27 - 45MRX-1 30-I

0
SWING GEAR PUMP FLOOR FRAME
Removal and Installation .......................... .30-93 Removal 30-I 88
PPC PUMP Installation 30-191
Removal and Installation .......................... .30-94 CANOPY
MAIN CONTROL VALVE Removal and Installation 30-192
Removal ..................................................... .30-96 OPERATOR’S CAB
Installation ................................................. .30-97 Removal 30-I 93
Disassembly ............................................ .30-102 Installation 30-194
Assembly .................................................. 30-104 COUNTERWEIGHT
WORK EQUIPMENT LEFT PPC VALVE Removal and Installation ..... ....... . .... .. . 30-195
(FOR ARM, SWING CONTROL) HYDRAULIC BREAKER
Removal and Installation ......................... 30-131 Disassembly ..... . .... . ...... ...... . ...... .... 30-192
WORK EQUIPMENT RIGHT PPC VALVE Assembly ........ . ......... . .. ...... . . ...... .. 30-203
(FOR ~00~ AND BUCKET CONTROL)
Removal and Installation ......................... 30-133
WORK EQUIPMENT PPC VALVE
Disassembly ............................................ .30-135
Assembly .................................................. 30-I 36
BOOM CYLINDER
Removal and Installation ......................... 30-137
ARM CYLINDER
Removal and Installation ......................... 30-140
BUCKET CYLINDER
Removal and Installation ......................... 30-143
SWING CYLINDER
Removal and Installation ......................... 30-146
BLADE CYLINDER
Removal and Installation ........................ .30-l 52
HYDRAULIC CYLINDER
Disassembly ............................................ .30-155
Assembly ................................................. .30-l 58
WORK EQUIPMENT
Removal and Installation ........................ .30-l 62
BUCKET
Removal and Installation ........................ .30-l 65
ARM
Removal and Installation ........................ .30-l 67
BUCKET, ARM
Removal and Installation ........................ .30-l 70
SWING BRACKET
Removal and Installation ........................ .30-l 73
BLADE
Removal and Installation ......................... 30-176
SEAT BRACKET, R.H. AND L.H. PPC VALBE
Removal ................................................... .30-l 79
Installation ............................................... .30-181
SEAT BRACKET
Removal ................................................... .30-l 82
Installation ............................................... .30-182
SOLENOID VALBE
Removal ................................................... .30-l 83
Installation ............................................... .30-184
HEATER
Removal and Installation ......................... 30-187

30-2 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

METHOD OF USING MANUAL

1. When removing or installing unit assemblies
@I When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
@ Any special techniques applying only to the installation procedure are marked a, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.

(Example)
REMOVAL OF 0000 ASSEMBLY .. . . . . . .. . . . . . . Title of operation

. .. . .. . . . .. .. . .. . . . . . . .. . . . .. . . . .. . . .. . . .. . . . .. . .. . . . . . . .. .. . . . .. . .. . . Precautions related to safety when carrying out

the operation
1. XXXX(1) . . . . . . . . . . .. . .. .. . .. .. . .. . . . . . . .. . .. . . . . . .. .. . . . . .. . . Step in operation
* .. .. . .. . .. . . . . . .. . . .. . . .. . .. .. . .. . .. . . . .. . . . . . . . . .. . .. . . . . . .. . .. . . Technique or important point to remember
when removing XXXX (1).
2. A A A A (2): . . .. .. . . .. . .. . . . . .. . . . . .. . . .. . . . . .. .. . . . . . . .. . . m Indicates that a technique is listed for use
during installation
3. 0 0 0 0 assembly (3)

.......... .. .................................. ..... ...... ........... Quantity of oil or water drained

l
INSTALLATION OF 0000 ASSEMBLY . . . . .Title of operation
Carry out installation in the reverse order to removal.
p .................. .......... .... ....... ..................... . Technique used during installation
. . .. . . . . .. . . .. . . . . . . . . . .. ... .. . .. .. . .. . . . . . .. .. .. . . . . . . .. . . . . . .. . . Technique or important point to remember when
installing A A A A (2).
l Adding water, oil . . . .. . . .. . .. . . . . . . . .. . . . . . . .. . . . . Step in operation
* . . .. . .. . . . .. . . . .. . . . . .. . . . .. . .. . . . . .. . . .. . . . . . .. .. . . . . .. .. . . Point to remember when adding water or oil

.. . . . . . . . . .. .. . . .. .. . .. . .. . . . .. . . . .. . . . .. . .. . . . . . .. . . . . . . Quantity when filling with oil and water

2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.

3. Listing of special tools

@ For details of the description, part number, and quantity of any tools (Al, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

PC27 - 45MRX-1 30-3

0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.
. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
Ir Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations,

Nominal
Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 0737650210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut),07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut),07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut),07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)

1) Hoses and tubes using sleeve nuts

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

2) Split flange type hoses and tubes

3) If the part is not under hydraulic pressure, the following corks can be used.

DEW00401

30-4 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.

When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times,
stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
* When using the machine for the first time after repair or long storage, follow the same
procedure.

Precautions when completing the operation

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
* For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

PC27 - 45MRX- 1 30-5

0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

SPECIAL TOOL LIST

* Tools with part number 79OT-000-0000 cannot be supplied (they are items to be locally manu-
factured).
* Necessity: w : . . .. . . ... . Cannot be substituted, should always be installed (used)
a : . . .. .. .. . . Extremely useful if available, can be substituted with commercially avail-
able 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, used without any modification
* Tools marked 0 in the Sketch column are tools introduced in special sketches.

Component
Ts T
;ym boII

PC40045MRX

Disassembly, assem-
bly of swing motor, F
swing machinery

Press fitting of bushing

Disassembly, assem-
bly of idler assembly

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

Component ymbol
ewi Ske.
Nature of work, remarks
ze, tch

3
Disassembly,
assembly of track
roller assembly

-
4
-7
‘C27’30*35MR installation
floating SeaI
of

5 Press fitting of bearing and

cap
Disassembly,
assembly of carrier
roller assembly

Press fitting of carrier roller

6
oil seal

Disassembly, Removal, installation of

assembly of recoil spring
P.Q.S.spring assembly
_

790-501-5000
1

Disassembly, assembly of
motor assembly
2
3
4 NO
2- Removal of brake piston

2 NO Disassembly, assembly of
cylinder block assembly
3 3
Disassembly,
assembly of swing 1 4
motor assembly

1
1
4 Press fitting of sub-bearing
2

5 N Assembly of motor assembly

1 790-101-5201
2 790-101-5261 * Plate I
6 Fitting of spacer
3 790-101-5221 - Grip I
4 01010-51225 * Bolt I
1 790-201-2110 Plate I
7 Press fitting of main bearing
t 2 790-201-2710 Spacer I

790-101-1430 Coupler assembly m Release of brake

(For measurement of
796-660-I 490 Nipple I turning torque)

30-8 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

Component
T
5iymbol
I
Part No.
I
Part Name
TI
h
Nature of work, remarks

13 1 799-101-5130 1 Gauge

14 1 799-101-5160 1 Nipple
15 I 799-301-1190 I Nipple
Release of brake
I 16 I 799-301-1660 I T-piece (For measurement of
Disassembly, 17 I 205-70-51390 I Nipple turning torque)
assembly of swing
motor assembly I s I 790-301-1210 I Joint

19 I 07002-11423 I O-ring
I 1 I 796-720-3510 I Wrench
Measurement of turning
I I 2 I 01306-10606 I Set screw torque of shaft
I 3 I 795-630-1803 I Torque wrench

II I 790-501-5200
Unit repair stand
(for 220, 240V)
Disassembly,
pump
assembly of

2 790-901-2110 Bracket

3 796T-267-1130 Plate

I Removal of sub bearing

inner race
I
I
2 796T-267-1220 Washer I Disassembly, assembly of
s cylinder block assembly
3 01643-31445 Washer I
Disassembly,
14 1 01580-01210 1 Nut I
assembly of hydrau- I 790-101-5001 I Push tool KIT I
lic pump assembly
- 790-101-5061 Plate Press fitting of main
4
- 790-101-5021 Grip bearing outer race

Press fitting of main

5 796-l 26-l 140 Push tool I bearing inner race

Press fitting of sub

6 796T-267-1240 Push tool I bearing inner race

I 790-101-5001 1 Push tool KIT I

* 790-101-5051 Plate
7 Press fitting of sub bearing
* 790-101-5021 Grip outer race

1 * 01010-50816 1 Bolt
I Measuring drive shaft
I rotating torque

I Press fittinq of oil seal

Disassembly, assem-
Disassembly, assembly of
bly of hydraulic pump t
assembly pump

PC27 - 45MRX-1 30-8-I

0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

NeWI
Ske_
Component Symbol Part No. Part Name 1% Q’ty ,‘,;,, tch Nature of work, remarks

Disassembly, assembly of

Disassembly, assembly of
cylinder block assembly

Press fitting of ball bearing

Disassembly, assem-
bly of hydraulic pump
assembly Press fitting of needle

Measuring drive shaft

Press fitting of needle

Disassembly,
assembly of center T 1 * 790-101-2540 1 *Washer I III I Separation of shaft and
swivel joint assembly rotor
I - 790-101-2630 I - Lea I 121 I
1 . 790-101-2570 1 * Plate I 141 I
1 . 790-101-2560 1 . Nut I 121 I
I * 790-101-2660 I * Adapter I 121 I
1 790-502-I 003 1 Unit repair stand I= 11 1 1 Disassembly, assembly of
790-101-1102 1 Hydraulic pump I= 11 1 1 hydraulic cylinder

Removal, installation of
2 790-330-I 100 Wrench assembly n 1
cylinder head
I I I I
Disassembly,
assembly of hydraulic U On the market Socket n I across flats :
cylinder assembly 36mm Nut

3 On the market Socket n I across flats : installation

On the market Socket n I across flats :

46mm Nut

30-8-2 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

Component
T T
Slymbol Part No. Part Name 1;; Q’ty ;$, ;z Nature of work, remarks

I
790-302-I 270 Socket

790-302-I 490 Socket n lN For width across

flats : 50mm Nut
790-102-I 520 Adapter n I (lono) Removal,
3 installation
For Width across
of piston nut
790-302-1280 Socket n 1 flats : 55mm Nut
(short)
790-302-1470 Socket n 1 For width across
flats : 55mm Nut
790-102-1520 Adapter n 1 (Ions)

Press fitting of cylinder

790-210-1702 Push tool KIT

- 790-201-I 761 ide diameter :

790-201-I 500 head dust seal

I I I I I I
Disassembly,
assembly of hydraulic 1
cylinder assembly * 790-201-I 540 - Plate I I 1I I I !l!k%hdiinagm-
eter : 40mm
For bushing
* 790-201-1550 * Plate 1 outside diam-
eter : 45mm
5
For bushing
. 790-201-1560 * Plate 1 outside diam-
eter : 50mm
For bushing
. 790-201-1570 * Plate 1 outside diam-
eter : 55mm
. 790-101-5021 * Grip 1

PC27 - 45MRX-1 30-8-3

0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these sketches.

PI-4 Plate

p0

t9
4-13.6 DRILL f
/ CUP06341

h L HEAT TREATMENT MATERIAL

SSjpyO P
Cl0
PART NAME

127.MO. 2 20
f
PLATE 3
PART NO.
796T-126-l 180

PC27 - 45MRX-1 30-9

0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

P3-2 Washer

3 CUP06343
HEAT TREATMENT MATERIAL
SSjpYOB
PART NAME
WASHER 1
PART NO.
_
79EiT 136 1160_

P5 Guide

CUP06344
HEAT TREATMENT MATERIAL
SSjpYOB
PART NAME
GUIDE 1
PART NO.
-
79bT 136 1170-

30-9-I PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

91. Plate

DWPO2124
HEAT TREATMENT MATERIAL

t9 SS4OOP
PART NAME Cl'
TY
PLATE
Unless specified,
flashes and
check
burrs.
all cornere for
v
796T-267-1 130 ‘A

Q2-1. Plate

DWP02125

\/ HEAT TREATMENT 1 MATERIAL

V
Unless specified. check all corners for flashes and burrs. SEE DWG
PART NAME 0' TY
02 PLATE SS4OOP 2 0.01 t3
PLATE
01 PLATE 1.59 t9
SYM. PART NAME MATERIAL QTY/SET "(;;f REMARKS 796T-267-1250 ‘A

PC27-45MRX-1 30-9-2
0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

Q3-2. Washer

24

DWP02126
HEAT TREATMENT MATERIAL
Unless specified, check all corners for flashes and burrs.

Q6. Push tool

DWPO2127

Unless specified, check all corners for flashes and burrs. “,,,

1 796T-267-1240 A

30-9-3 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

99. Push tool

c-4

z
z
-.
I.0

co. El___ co. 5_ _ $

co. 5 _co. 5

100

PC27 - 45MRX-1 30-9-4

0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

Sl. Plate

335 25
t
670
720
DWP02124
HEAT TREATMENT 1 MATERIAL

t9 SS4OOP
PART NAME Q’ TY
PLATE 1
Unless specified,
flashes and
check
burrs.
all corners for
v 1 796T-267-1130 fi

S2. Washer

DWP02128

Unless sDecified, check all corners for flashes and burrs. ‘,,,”

1 796T-167-1110 n

30-9-5 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR

REMOVAL OF STARTING
MOTOR ASSEMBLY
PC27MRX, PC30MRX

a Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
a Disconnect the cable from the negative (-) ter-
minal of the battery.

Remove seat bracket and right and left PPC valve

assembly. For details, see REMOVAL OF SEAT
BRACKET, R.H. AND L.H. PPC VALVE ASSEMBLY.

Disconnect wiring connector (1) (T4).

Remove the boots, then disconnect 2 wires (2).

Remove starting motor assembly (3).

-T-----.\ lvGiph&-- CWPO6279

INSTALLATION OF STARTING
MOTOR ASSEMBLY
PC27MRX, PC30MRX

l Carry out installation in the reverse order to re-

moval.

30-10 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR

REMOVAL OF STARTING
MOTOR ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

A Disconnect
. the cable from the negative (-) ter-
minal of the battery.

1. Remove air-conditioner unit assembly.

Ir For operator cabin specification machine only.

2. Remove inspection cover (1) at under of operator’s

seat.

3. Disconnect wiring connector (2).

Ir Wiring connector (T4) : PC35MRX
J, Wiring connector (MIO) : PC40MRX, PC45MRX

4. Remove the boots and disconnect 2 wire (3).

5. Remove starting motor assembly (4).

INSTALLATION OF STARTING
MOTOR ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

PC27 - 45MRX- 1 30-l 1

0
DISASSEMBLY AND ASSEMBLY ALTERNATOR

REMOVAL OF ALTERNATOR
ASSEMBLY
PC27MRX, PC30MRX

g Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Disconnect the cable from the negative (-1 ter-
minal of the battery.

1. Remove the cover (I 1.

2. Disconnect connector (2) (El) and (3) (E2).

3. Disconnect water temperature sensor connector

(4) (E7). .3

4. Remove adjustment bolt (5).

.2

5. Loosen mounting bolt, and remove alternator belt

(7). m

6. Remove mounting bolt (6) and remove the alter-

nator assembly (8).

CWPO6292

INSTALLATION OF ALTERNATOR
ASSEMBLY
PC27MRX, PC30MRX

l Carry out installation in the reverse order to re-

moval.

* Adjust the alternator belt. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing alternator belt tension.

30-l 2 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY ALTERNATOR

REMOVAL OF ALTERNATOR
ASSEMBLY
PC35MRX

A Disconnect
. the cable from the negative (-1 ter-
minal of the battery.

1. Remove the right lever stand assembly (I) with

mounting bracket.

Disconnect wiring connector (2) (El,E2).

Disconnect wire (3).

Loosen mounting bolt and adjustment bolt (4).

Remove adjustment bracket (51, then remove fan

belt (6) from pulley. [a
* It is not enable to remove the fan belt from
pulley, after remove adjustment bracket.
-k There are spacers fitted to the adjustment
bolts so be careful not to drop them.

6. Remove the alternator assembly (7).

+ There are spacers fitted to the mounting bolts
so be careful not to drop them.

INSTALLATION OF ALTERNATOR
ASSEMBLY
PC35MRX

l Carry out installation in the reverse order to re-

moval.

Adjust the alternator belt. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing alternator belt tension.

PC27 - 45MRX- 1 30-l 3

0
DISASSEMBLY AND ASSEMBLY ALTERNATOR

REMOVAL OF ALTERNATOR
ASSEMBLY
PC40MRX, PC45MRX

A Drsconnect
. the cable from the negative (-) ter-
minal of the battery.

1. Remove the right side upper cover.

2. Remove the cover (I) between operator’s cab and

hydraulic tank.

3. Disconnect wiring connector (2) (M8, M9).

4. Disconnect wire (3).

5. Loosen mounting bolt and adjustment bolt (4).

6. Remove adjustment bracket (51, then remove fan

belt (6) from pulley. a
* It is not enable to remove the fan belt from
pulley, after remove adjustment bracket.
Sr There are spacers fitted to the adjustment
bolts so be careful not to drop them.

7. Remove the alternator assembly.

* There are spacers fitted to the mounting bolts
so be careful not to drop them.

INSTALLATION OF ALTERNATOR
ASSEMBLY
PC45MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

* Adjust the alternator belt. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing alternator belt tension.

30-14 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
PC27MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
g ground and stop the engine.
Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Pull out the fuel control cable pin (I).

2. Disconnect engine stop solenoid wiring connec-

tor (2) (E3).

3. Remove lubrication tube (3).

4. Disconnect fuel supply hose (4).

5. Disconnect fuel return hose(5).

Ir Spill hose is jointed to fuel return hose.

6. Disconnect 3 fuel injection tubes (6). m

7. Remove the cover (7).

8. Remove the injection mounting nut (8). a

Ir Make sure the impressed mark position.

9. Remove the drive gear mounting nut (9). m

10. Be careful not to drop the nut and washer into

the front cover.
Make the matching mark with white paint on
the drive gear and idler gear.

11. Remove fuel injection pump assembly (IO).

* Using puller 0, push the fuel injection pump
cam shaft and disconnect drive gear, then re-
move fuel injection pump assembly.
* Be careful not to drop the woodruff key into
the case.

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

INSTALLATION OF FUEL INJECTION

PUMP ASSEMBLY
PC27MRX

l Carry out installation in the reverse order to re-

moval.

m Sleeve nut : 25.5 f 1.0 Nm I2.6 f 0.1 kgm}

m
* Align the case impressed mark, then tighten
the nut.

m Mounting nut: 3.9f 1.0 Nm IO.4i 0.1 kgm}

113
Ir Align the gear marching marks, then tighten
the nut.

w Mounting nut:
58.8 f 1.0 Nm IS.0 + 0.1 kgm}

30-l 6 PC27 - ISMRX- 1

0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
PC30MRX, PC35MRX, PC45MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Disconnect the cable from the negative (-1 ter-
minal of the battery.

1. Remove counter weight. For details, see RE-

MOVAL OF COUNTER WHIGHT ASSEMBLY.

2. Pull out the fuel control cable pin (I) and discon-
nect cable from bracket. m
Ir Check the mounting length, before disconnect
bracket.

3. Disconnect engine stop solenoid wiring connec-

tor (2).
Ir Wiring connector (E3) :
PC27MRX, PC30MRX, PC35MRX
* Wiring connector (M13) : PC40MRX. PC45MRX

4. Remove lubrication tube (3).

5. Disconnect fuel supply hose (4).

6. Disconnect fuel return hose(5).

* Spill hose is jointed to fuel return hose.

7. Disconnect 3 fuel injection tubes (6)

Ir PC27MRX, PC30MRX, PC35MRX : 3 tubes
Sr PC40MRX, PC45MRX : 4 tubes

8. Remove the cover (7).

9. Remove the injection mounting nut (8). 112

* Make sure the impressed mark..

10. Remove the drive gear mounting nut (9). m

Be careful not to drop the nut and washer into
the front cover.
Make the matching mark with white paint on
the drive gear and idler gear.
When it is difficult to make the marching mark,
remove radiator l hydraulic cooler assembly.
For details, see REMOVAL OF RADIATOR HY-
l

DRAULIC COOLER ASSEMBLY.

11. Remove fuel injection pump assembly (IO).

Ir Using puller 0, push the fuel injection pump
cam shaft and disconnect drive gear, then re-
move fuel injection pump assembly.
* Be careful not to drop the woodruff key into
the case.

PC27 - 45MRX- 1 30-17

0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

INSTALLATION OF FUEL INJECTION

PUMP ASSEMBLY
PCSOMR, PC35MR, PC40MR, PC45MR

l Carry out installation in the reverse order to re-

moval.

m
* Adjust the fuel control cable. For detail, see
TESTING AND ADUJUSTING, Adjusting fuel
control cable.

m
* Align the case impressed mark, then tighten
the nut.

m Injection pump mounting nut :

20.58 + 0.98 Nm I2.1 * 0.1 kgm}

w
Ir Align the gear marching marks, then tighten
the nut.

QK! Drive gear mounting nut :

63.7 + 4.9 Nm 16.5 + 0.5 kgm}

30-18 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

REMOVAL OF NOZZLE HOLDER

ASSEMBLY
PC27MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove air inlet hoses (I) and (2).

2. Remove the mounting bolt (3) and remove air

cleaner assembly (4).

3. Remove air cleaner mounting bracket (5).

4. Remove fuel injection tube (6). m

5. Disconnect spill hose, then remove retainer (7).

6. Remove nozzle holder assembly (8).

INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
PC27MRX

l Carry out installation in the reverse order to re-

moval.

m
w Sleeve nut : 25.5 + 1.0 Nm (2.6 f 0.1 kgm}

B Retainer mounting nut :

3.9 _+1.0 Nm to.4 f 0.1 kgm)

When assembling the nozzle holder, clean the

nozzle holder mount, and check that there is
no dust inside the sleeve before assembling.

PC27 - 45MRX- 1 30-19

0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

REMOVAL OF NOZZLE HOLDER

ASSEMBLY
PCSOMRX, PC35MRX, PC4OMRX, PC45MRX

g Stop the machine on the horizontal ground, then

lower the work equipment completely to the

negative (-) ter-

1. Remove air inlet hoses (I 1 and (2). m

2. Remove the mounting bolt (3) ,then remove air

cleaner assembly (4).

3. Remove air cleaner mounting bracket (5).

4. Remove fuel injection tube (6).

5. Disconnect spill hose (7).

6. Remove retainer (8).

7. Remove nozzle holder assembly (9).

INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
PCSOMRX, PC35MRX, PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

m Intake air hose clamp :

5.9 ? 0.49 Nm {SO + 5 kgcml

m Retainer mounting nut :

4.41 + 0.49 Nm (0.45 + 0.05 kgml

* When assembling the nozzle holder, clean the

nozzle holder mount, and check that there is
no dust inside the sleeve before assembling.

30-20 PC27 - 45MRX- 1

DISASSEMBLY AND ASSEMBLY WATER PUMP

REMOVAL OF WATER PUMP

ASSEMBLY
A Stop the machine on the horizontal ground, then
lower the work equipment completely to the
ground and stop the engine.
a Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove radiator oil cooler assembly (1). For de-

l

tails, see REMOVE OF RADIATOR HYDRAULIC

l

COOLER ASSEMBLY.

2. Loosen alternator mounting bolt, then remove al-

ternator belt (2) from alternator pulley. m

3. Remove fan (3) mounting bolt. then remove pul-

ley (4) and alternator belt together.
+ Fan pulley and fan are tighten together.

4. Remove mounting bolt (5), then remove the wa-

ter pump assembly (6). m

INSTALLATION OF WATER
PUMP ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

Ir Adjust the alternator belt tension. For details,

see TESTING AND ADJUSTING, testing and
adjusting alternator belt tension.

w Water pump mounting bolt :

10.78 f 1.96 Nm Il.1 f 0.2 kgm}

l Refilling with water

Add water through water filler to the specified
level. Run the engine to circulate the water
through the system. Then check the water level
by reserve tank again.

PC27 - 45MRX- 1 30-21

a
DISASSEMBLY AND ASSEMBLY THERMOSTAT

REMOVAL OF THERMOSTAT
ASSEMBLY
g Stop the machine on the horizontal ground, then
lower the work equipment completely to the
ground and stop the engine.

1. Disconnect radiator inlet hose (I ). m

2. Remove mounting bolt, then remove cover (2).

3. Remove thermostat assembly (3).

IIINSTALLATION OF
THERMOSTAT ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

QFI Radiator inlet hose clamp :

8.8 f 0.5 Nm I90 + 5 kgcml

l Refilling with water

Add water through water filler to the specified
level. Run the engine to circulate the water
through the system. Then check the water level
by reserve tank again.

30-22 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL

REMOVAL OF ENGINE FRONT

SEAL
1. Remove radiator and hydraulic cooler assembly.
For details, see REMOVAL OF RADIATOR HY-
DRAULIC COOLER ASSEMBLY.

2. Loosen alternator mounting bolt, then remove al-

ternator belt (2) from alternator pulley. m

3. Remove fan (3) mounting bolt. then remove pul-

ley (4) and alternator belt together.
Ir Fan pulley and fan are tighten together.

4. Remove bolt (5) and spacer (61, and tighten the

bolt (5) 2 to 4 turns again, then remove crank pul-
ley (7) using puller 0. 112

5. Remove engine front seal (8). a

INSTALLATION OF ENGINE
FRONT SEAL w /1 CWPO6406

l Carry out installation in the reverse order to re-

moval.

Ir Adjust the alternator belt tension. For details,

see TESTING AND ADJUSTING, Testing and
adjusting alternator belt tension.

m Crankshaft pulley mounting bolt :

112.7+~* Nm {11.5+:” kgm}
I
CWPO6407

& Lip of oil seal : Engine oil (EOSO-CD)

PC27 - 45MRX- 1 30-23

0
DISASSEMBLY AND ASSEMBLY
ENGINE REAR SEAL

REMOVING OF ENGINE REAR

SEAL
1. Remove the damper assembly. For details, see
REMOVAL OF DAMPER ASSEMBLY

2. Remove the flywheel (1). m

3. Remove the seal case (2). a

* Since the seal case has notches on the both
ends, prize the case with screwdriver to re-
move it.

4. Remove the engine rear seal (3) from the seal

case. m

CLPO2630

30-24
PC27 - 45MRX- 1
0
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

INSTALLATION OF ENGINE
REAR SEAL
. Carry out installation in the reverse order to re-
moval.

,Q& Seal mounting face of seal case and oil seal

lip : Engine oil (E030XD)

Ir Press fit the oil seal until it comes to the same

level as the seal case.

6 Seal case mounting face :

Gasket sealant (LG-7)

* Tighten the flywheel mounting bolts in the or-

der shown in the drawing on the right.

w Flywheel mounting bolt :

85.75 f 2.45 Nm 18.75 k 0.25 kgm)

* After installing the flywheel, check it for fa-

cial runout and radial runout with dial gauge
0.
l Facial runout : 0.20mm max.
l Radial runout : 0.20mm max.

PC27 - 45MRX-1 30-25

0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

REMOVAL OF CYLINDER HEAD

ASSEMBLY
a Stop the machine on the horizontal ground, then
lower the work equipment completely to the
ground and stop the engine.
a Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove seat bracket, right and left PPC valve as-

sembly. For details, see REMOVAL OF SEAT
BRACKET, R.H. AND L.H. PPC VALVE ASSEMBLY.
(PC27MRX, PC30MRX)
2. Remove seat bracket assembly. For details, see
REMOVAL OF SEAT BRACKET ASSEMBLY.
(PC35MRX)
3. Remove floor frame assembly. For details, see RE-
MOVAL OF FLOOR FRAME ASSEMBLY.
(PC40MRX, PC45MRX)
4. Remove counterweight assembly. For details, see
REMOVAL OF COUNTERWEIGHT ASSEMBLY.

5. Disconnect air intake hose (21, (3).

6. Remove air cleaner (4).

7. Remove air cleaner bracket (5).

8. Disconnect fuel filter (6) from cylinder head.

9. Disconnect fuel injection tube (7).

10. Disconnect heater wire (8) from intake manifold.

11. Disconnect spill hose (9).

12. Disconnect wiring connector (IO) from intake

manifold.
Sr Wiring connector (E3) :
PC27MRX, PC30MRX, PC35MRX
Ir Wiring connector (M13) : PC40MRX, PC45MRX

30-26 PC27 - 45MRX- 1

a
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

13. Disconnect bracket (11) mounting bolt from en-

gine block, then remove muffler (12).
t Before disconnect mounting bolt, remove
muffler from exhaust manifold.

14. Remove exhaust manifold (13).

15. Disconnect wiring connector (14).

* Wiring connector (E7):
PC27MRX, PC30MRX, PC35MRX
Ir Wiring connector (P2): PC40MRX, PC45MRX

16. Remove alternator adjusting bracket (15). m

17. Remove radiator, hydraulic cooler assembly. For

details, see REMOVAL OF RADIATOR, HYDRAU-
LIC COOLER ASSEMBLY.

18. Remove alternator belt (17) and fan (18).

19. Remove water pump mounting bolt, then remove

water pump assembly (19).

i8
CWPO6418

20. Remove cylinder head cover (20).

21. Disconnect spill hose (21), then remove nozzle

holder assembly (22) after remove retainer. m

22. Remove rocker arm assembly. m

* Loosen the locknut, then loosen the adjust-
ment screw 2 to 3 turns.

23. Remove push rod (24).

24. Remove cylinder head mounting bolts, then re-

move cylinder head assembly (26). m
* Disconnect air intake manifold, after remove
cylinder head.

PC27 - 45MRX-1 30-27

0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

INSTALLATION OF CYLINDER
HEAD ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

w Intake hose clamp :

5.9 f 0.49 Nm I60 f 5 kgcm}

* Adjust the alternator belt tension. For details,

see TESTING AND ADJUSTING, Testing and
adjusting alternator belt tension.

w Retainer mounting nut :

4.41 + 0.49 Nm IO.45 f 0.05 kgml

* When tightening the mounting bolts, start

from the center and work to the outside in
turn.

m Rocker arm assembly mounting bolt :

7.8 f 0.98 Nm IO.8 * 0.1 kgm}
(PC27MRX)
25.48 + 2.94 Nm t2.6 f 0.3 kgml
(PC30, PC35, PC40, PC45MRX)

Check that the ball of the adjustment screw is

securely fitted in the socket of the push rod.
Adjust the valve clearance. For details, see
TESTING AND ADJUSTING, Adjusting valve
clearance.

Tighten the cylinder head assembly mount-

ing bolts in the order shown in the diagram
on the right. Exhaust side

m Cylinder head assembly mounting bolt

(PC27MRX) : 68.6 + 1.96 Nm t7 + 0.2 kgml
fg);;;

QKI Cylinder head assembly mounting bolt

(PC30MRX. PC35MRX. PC4OMRX. PC45MRX) :

06 06 0Y
fl I
Intake side

DKP00465

l Refilling with water

Add water through water filler to the specified
level. Run the engine to circulate the water
through the system. Then check the water level
by reserve tank again.

30-28 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER

REMOVAL OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY
PC27MRX, PCSOMRX, PC35MRX

a Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the pressure inside the hydraulic tank.
For details, see TESTING AND ADJUSTING, Re-
leasing remaining pressure from hydraulic tank.

1. Remove seat bracket, right and left PPC valve as-

WPO6412
sembly. For details, see REMOVAL OF SEAT
BRACKET, R.H. AND L.H. PPC VALVE ASSEMBLY.
(PC27MRX, PC30MRX)

2. Remove counterweight assembly. For details, see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.

3. Drain coolant.

4 Disconnect radiator cross hose (2) and upper hose

(3) at water pump side. m

5 Disconnect air cleaner intake hose (4). m

6. Remove fan guard (5).

7. Remove fan (6), pulley (7) and alternator drive belt

(8) together. m
* Fan pulley (7) and fan (6) are tighten together.
* Remove these for draw out the radiator.

8. Disconnect coolant drain hose (9).

8’7 6
CWP06423

9. Disconnect overflow hose (IO).

10. Disconnect hydraulic cooler inlet hose (II) and

outlet hose (12).

11. Remove hydraulic cooler assembly (13).

Sr Hose (11) is difficult to bend, so first remove
hydraulic cooler assembly, then remove ra-
diator assembly.

12. Remove radiator assembly (14) pulling towards

outside. ‘11 CWP06425

PC27 - 45MRX- 1
30-29
0
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER

INSTALLATION OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY
PC27MRX, PCBOMRX, PC35MRX

l Carry out installation in the reverse order to re-

moval.

w Radiator inlet hose and outlet hose clamp :

8.8 * 0.5 Nm I90 + 5 kgcm}

m Air intake hose clamp :

5.9 f 0.49 Nm {SO f 5 kgcm}

* Adjust the alternator belt tension. For details,

see TESTING AND ADJUSTING, Testing and
adjusting alternator belt tension.

l Refilling with water

Add water through water filler to the specified
level. Run the engine to circulate the water
through the system. Then check the water level
by reserve tank again.

l Refilling with oil (hydraulic tank)

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.

m Oil filler plug (PC35MRX) :

181.3-240.1 Nm 118.5-24.5 kgm}

30-30 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY RADIATOR. HYDRAULIC COOLER

REMOVAL OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY
PC40MRX, PC45MRX

a Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
a Release the pressure inside the hydraulic tank.
For details, see TESTING AND ADJUSTING, Re-
leasing remaining pressure from hydraulic tank.

1. Remove counterweight assembly. For details, see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.

2. Drain coolant.

3. Open right upper cover (I), then remove right

cover (2) and right lower cover (3).

4. Remove hydraulic cooler upper and lower cover

(4), (5).

5. Disconnect hydrauliccooler inlet hose (5) and out-

let hose (6).
* Put on the pipe plug to hydraulic cooler and
hoses.

6. Remove cover (7) from under of radiator.

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER

7. Remove fan guard (8).

8. Disconnect air intake hose (9).

9. Disconnect radiator inlet hose (10)and outlet hose

(II).

10. Disconnect drain hose (12).

11. Remove radiator upper bracket (13).

30-32 PC27 - 45M RX- 1

0
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER

12. Lift off radiator and hydraulic cooler assembly

(14). 3
0 Radiator and hydraulic cooler assembly :
25kg

INSTALLATION OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY
PC40MRX, PC45MRX

• Carry out installation in the reverse order to re-

moval.

1
9 Air intake hose clamp :
5.9 ± 0.49 Nm {60 ± 5 kgcm}

2
9 Radiator inlet hose and outlet hose clamp :
8.8 ± 0.5 Nm {90 ± 5 kgcm}

3
9 Radiator, hydraulic cooler assembly
mounting bolt : 59 – 74 Nm {6 – 7.5 kgm}

• Refilling with oil (hydraulic tank)

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.

• Refilling with water

Add water through water filler to the specified
level. Run the engine to circulate the water
through the system. Then check the water level
by reserve tank again.

PC27 – 45MRX-1 30-33

3
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP

REMOVAL OF ENGINE, MAIN

PUMP ASSEMBLY
PC27MRX, PC30MRX, PC35MRX

¤ Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
¤ Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Remove seat bracket, right and left PPC valve as-

sembly. For details, see REMOVAL OF SEAT
BRACKET, R.H. AND L.H. PPC VALVE ASSEMBLY.
(PC27MR, PC30MR)

2. Remove seat bracket assembly. For details, see

REMOVAL OF SEAT BRACKET ASSEMBLY.
(PC35MR)

3. Remove counterweight (1)

4. Drain coolant.

5. Drain hydraulic oil.

6 Hydraulic tank : Approx. 28.5 ¬

6. Disconnect radiator cross hose (2)and upper hose

(3) at water pump side. 1

7. Disconnect air cleaner intake hose (4) and (5).

2

8. Remove air cleaner(6), then remove bracket (7).

9. Remove fan guard (8).

10. Remove fan (9) mounting bolt, then alternator belt

(10) and pulley (11). 3

11. Disconnect coolant drain hose (12).

12. Disconnect radiator overflow hose (13).

13. Disconnect oil cooler inlet hose (14).

14. Disconnect oil cooler outlet hose (15), then re-

move oil cooler assembly.

15. Remove radiator assembly (17).

fl Remove radiator assembly, pulling towards
outside.

30-34 PC27 – 45MRX-1

3
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP

16. Disconnect the pipes from main pump assembly

shown under. (PC27MRX, PC30MRX)
l Suction tube : (18)
l Pump pressure inlet hose : (19)
l Main pump discharge pressure (PI) hose : (20)
l Gear pump discharge pressure (P2) hose : (21)
l LS pressure input hose : (22)

17. Disconnect the pipes from main pump assembly

shown under. (PC35MRX)
l Suction tube : (39)
l Pump pressure inlet hose : (40)
l Main pump discharge pressure (PI) hose : (41)
l Main pump discharge pressure (P2) hose : (42)
l Gear pump discharge pressure (P3) hose : (43)
l LS pressure input hose : (44)

18. Disconnect fuel control cable (23). m

* Pull out the pin, then disconnect the bracket.
* Make sure the mounting dimension before
disconnection.

19. Disconnect engine oil pressure switch wire (24)

(T5).

20. Disconnect fuel feed pump wiring connector (25)

(E4) and engine stop solenoid wiring connector
(26) (E3).
06431
21. Disconnect fuel feed pump inlet hose (27) and fuel
return hose (28).

22. Disconnect Air heater wire (29) (T9).

23. Disconnect starting motor wiring connector (30)

(T4).

24. Remove boots, then disconnect wire (31).

31 CWP06433

PC27 - 45MRX-1 30-35

0
 ENGINE, MAIN PUMP
DISASSEMBLY AND ASSEMBLY

25. Disconnect engine water temperature sensor wir-

ing connector (32) (E7).

26. Disconnect alternator wiring connector (33) (El)

and (34) (E2).

27. Disconnect alternator wire (35) (T3).

28. Disconnect 2 PPC pump discharge hoses.

(PC35MRX)

CWPO6435
29. Disconnect engine grounding wire (36).

30. Remove 4 engine mounting bolts (37).

31. Lift off engine main pump assembly (38).

* Using a lever block, adjust the balance of en-
gine main pump assembly, and lift off.

& kg Engine, main pump assembly : 190kg

PC27 - 45MRX-1
30-36
0
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP

INSTALLATION OF ENGINE,
MAIN PUMP ASSEMBLY
PC27MRX, PC30MRX, PC35MRX

l Carry out installation in the reverse order to re-

moval.

w Radiator inlet hose and outlet hose clamp :

8.8 k 0.5 Nm I90 f 5 kgcm}

w Air intake hose clamp :

5.9 + 6.49 Nm (60 f 5 kgm1

Adjust the alternator belt tension. For details,

see TESTING AND ADJUSTING, Testing and
adjusting alternator belt tension.

Adjust the fuel control cable. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing adjusting the fuel control cable.

l Refilling with oil (hydraulic tank)

Add oil through oil filler to the specified level. Run
the engine to circulate the oil through the sys-
tem. Then check the oil level again.

Hydraulic tank : approx. 28.5 e (EOIO-CD)

m oil filler plug (PC35MR) :

181.3 - 240.1 Nm 118.5 - 24.5 kgml

l Refilling with water

Add water through water filler to the specified
level. Run the engine to circulate the water
through the system. Then check the water level
again.

. Bleeding air
Bleed the air from the fuel system. For details,
see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-37

0
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP

REMOVAL OF ENGINE, MAIN

PUMP ASSEMBLY
PC40MRX, PC45MRX

Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the remaining
circuit and hydraulic
pressure in the hydraulic
tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.
A Disconnect the cable from the negative
minal of the battery.
(-) ter-

1. Drain coolant.

2. Drain hydraulic oil.

- : Hydraulic tank : Approx. 33 e

3. Remove canopy assembly. For details, see RE-

MOVAL OF CANOPY ASSEMBLY.

4. Remove operator cabin assembly. For details, see

REMOVAL OF OPERATOR’S CAB ASSEMBLY.

5. Remove counterweight assembly. For details, see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.

6. Remove cover (I).

7. Lift off cover (2) from upper of engine stay.

jc Canopy specification machine only.

&I kg Cover : 25 kg

8. Lift off upper of engine stay (3).

-Lr Disconnect 5 wiring clamps from engine up-
per stay.

&I kg Upper engine upperstay: 45 kg

9. Remove muffler from exhaust pipe (4). m

30-38 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP

10. Disconnect the pipes from main pump assembly

shown under.
l Suction tube : (5)
l Pump pressure inlet hose : (6)
l Main pump discharge pressure (PI) hose : (7)
l Main pump discharge pressure (P2) hose : (8)
l Gear pump discharge pressure (P3) hose : (9)
l LS pressure input hose : (IO)

11. Remove reserve tank (II).

12. Remove fan guard (12).

13. Disconnect radiator inlet hose (13) and outlet hose

(14).

14. Remove radiator shroud (15) from radiator.

t Move radiator to engine side.

15. Disconnect starting motor wiring connector (16)

(MIO) and wire (17).

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP

16. Disconnect engine water temperature sensor con-

nector wire (18) (P2).

17. Disconnect alternator wiring connector (19) (M81,

(M9) and wiring (20).

18. Disconnect 2 hoses (21) from PPC pump.

19. Disconnect fuel control cable (22). m

* Also disconnect cable clamp.
+ Make sure the mounting dimension before
disconnection.

20. Disconnect air heater wire (23) (T6).

21. Disconnect engine stop solenoid wiring connec-

tor (24) (M13), fuel feed pump wiring connector
(25) (M14) and engine oil pressure switch con-
nector (26) (M42).
* Disconnect clamp from harness.

22. Disconnect engine grounding wire (27).

23. Disconnect fuel inlet hose (28) and return hose

(29).
+ Fit a blind plug in the disconnected hose.

24. Lift off engine l main pump assembly

a
* Using a lever block, adjust the balance of en-
gine main pump assembly, and lift off.
l

+ When removing the engine main pump as-

l

sembly, be extremely careful not to damage

the radiator core.

&I kg Engine, main l pump assembly : 250kg

30-40 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP

INSTALLATION OF ENGINE,
MAIN PUMP ASSEMBLY
PCIQOMRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

w Exhaust pipe inside nut :

5.9 - 9.8 Nm IO.6 - 1 .O kgm1

w Exhaust pipe outside nut :

59 - 74 Nm IS.0 - 7.5 kgml

w Radiator inlet hose, outlet hose :

8.8 + 0.5 Nm (90 + 5 kgcm}

Sr Adjust the fuel control cable. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing adjusting the fuel control cable.

& Engine mounting bolt :

Thread tightener (LT-2)

Ir When coating, be careful not to get any thread

tightener on the rubber cushion.

m Engine mounting bolt :

59 - 74 Nm (6 - 7.5 kgm)

Refilling with oil (hydraulic tank)

Add oil through oil filler to the specified level. Run
the engine to circulate the oil through the sys-
tem. Then check the oil level again.

I& Hydraulic tank : approx. 33 @.(EOIO-CD)

Refilling with water

Add water through water filler to the specified
level. Run the engine to circulate the water
through the system. Then check the water level
again.

Bleeding air
Bleed the air from the fuel system. For details,
see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-41

0
DISASSEMBLY AND ASSEMBLY DAMPER

REMOVAL OF DAMPER ASSEMBLY

1. Remove main pump assembly. For details, see
REMOVAL OF MAIN PUMP ASSEMBLY.

2. Remove cover (I 1.

3. Remove damper assembly (2). m

CWPO6437

INSTALLATION OF DAMPER
ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

& Coupling spiine portion :

Anti-friction compound (LM-PI
2
& Damper assembly mounting bolt thread :
Tread tightener (LT-2)

* When coating the thread, be careful not to get CWPO6438

any thread tightener on the rubber portion.

& Damper mounting bolt seat :

Grease (G2-LI)

j, When coating the mounting bolt seat, be care-

ful not to get any thread portion.

w Damper assembly mounting bolt :

83.3 - 92.2 Nm I8.5 - 9.4 kgml

30-42 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
PC27MRX, PC30MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.
A Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove swing motor, swing machinery assem-

bly. For details, see REMOVAL OF SWING MO-
TOR, SWING MACHINERY ASSEMBLY.
2. Disconnect drain hoses (1).
3. Disconnect right and left travel motor hoses (2)
snd (3).
4. Disconnect blade cylinder hose (4).
5. Disconnect left travel motor speed selector hose
15).
6. Disconnect drain hoses (6).
7. Disconnect right and left travel motor hoses (7)
and (8). 6
8. Disconnect blade cylinder hose (9). - CWPOG
9. Disconnect right travel motor hose (reverse) (10).
10. Disconnect right travel motor speed selector hose
:ll).
11. Disconnect left travel motor hose (forward) (12).
12. Disconnect hose (13) to blade cylinder head.
13. Disconnect right travel motor hose (reverse) (14).
14. Disconnect left travel motor hose (forward) (15).
15. Disconnect hose (16) to blade cylinder bottom.
16. Disconnect drain hoses (17).
17. qemove clamper bracket (18)
18. qemove swivel joint mounting bolts, then remove
:enter swivel joint assembly (19).

INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
PC27MRX, PC30MRX

l Carry out installation in the reverse order to re-

moval.

l 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.

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
PC35MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove swing motor lswing machinery assem-

bly. For details, see REMOVAL OF SWING MO-
TOR SWING MACHINERY ASSEMBLY.
l

2. Remove truck frame under cover.

3. Disconnect under right and left 8 hoses (I) from

under of center swivel joint assembly.
* Fit blind plugs in disconnected hose.
+ After disconnecting the hoses, fit tags to dis-
tinguish them.

4. Remove travel motor drain hose elbow (2).

5. Disconnect 8 hoses (3) from upper of center

swivel joint assembly.
* Fit blind plugs in disconnected hose.
* After disconnecting the hoses, fit tags to dis-
tinguish them.

6. Remove lock lever (4) from center swivel joint

assembly. a

7. Remove swivel joint assembly (5).

30-44 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
PC35MRX

l Carry out installation in the reverse order to re-

moval.

& Lock lever mounting bolt thread :

Tread tightener (LT-21

w Lock lever mounting bolt :

157 - 196 Nm {IS - 20 kgm}

l 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.

m Filler plug (PC35MRX) :

181.3 - 240.1 Nm (18.5 - 24.5 kgm}

l Bleeding air
Bleed the air from the fuel system. For details,
see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX-1 30-45

a
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
PC40MRX, PC45MRX

Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove floor frame assembly. For details, see RE-

MOVAL OF, FLOOR FRAME ASSEMBLY.
2. Remove truck frame under cover.
3. Disconnect 8 hoses (I) from upper of center swivel
joint assembly.
* Fit blind plugs in disconnected hose.
* After disconnecting the hoses, fit tags to dis-
tinguish them.
4. Remove lock lever (2) from center swivel joint
assembly. m
5. Disconnect right and left IO hoses (3) from under
of center swivel joint assembly.
j, Fit blind plugs in disconnected hose.
* After disconnecting the hoses, fit tags to dis-
tinguish them.
6. Remove travel motor drain hose elbow (4).
7. Remove swivel joint assembly (5).

INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

& Detent lever mounting bolt thread :

Tread tightener (LT-2)

m Detent lever mounting bolt :

153 - 190 Nm 115.5 - 19.5 kgm)

l 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.

l Bleeding air
Bleed the air from the fuel system. For details,
see TESTING AND ADJUSTING, Bleeding air.

30-46 PC27 - 45MRX-1

a
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

DISASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY
PC27MRX

1. Remove plate (1).

2. Remove snap ring (2).

3. Remove shaft assembly (3).

4. Remove dust seal (4) from shaft assembly (3).

5. Remove 3 plugs (5) and 4 plugs (6) from shaft

assembly (3).

6. Remove 8 O-ring (7)and 2 back-up ring (8) from

swivel rotor (9).

ASSEMBLY OF CENTER SWIVEL

JOINT ASSEMBLY
PC27MRX

1. Install 8 O-ring (7)and 2 back-up ring (8) to swivel

rotor (9).

2. Install 3 plugs (5) and 4 plugs (6) to shaft assem-

bly (3).
* Remove all oil and grease from the plug
thread, then dry the thread. Whole circumfer-
ence of thread : Thread tightener (LOCKTIGHT
542)

w Plug (5) : 4.90 - 6.86 Nm IO.5 - 0.7 kgm)

Plug (6) : 11.8 - 24.7 Nm Il.2 - 2.5 kgm}

3. Install dust seal (4) to shaft assembly (3).

CAP03053
& Lip of dust seal and rotor, shaft contact face
: Grease lG2-LI)

4. Install shaft assembly (3).

* Be careful not to damage the O-ring when in-
stalling.

5. Install spacer (9) and secure with snap ring (2).

6. Install plate (I)

m Mounting bolt :
11.8 - 14.7 Nm Il.2 - 1.5 kgm)

PC27 - 45MRX- 1 30-47

a
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

DISASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY
PCSOMRX

1. Remove 4 mounting bolts (2) from rotor (I), then

remove cover (3).

2. Remove 4 O-rings (4) from rotor (1).

3. Remove snap ring (5) from rotor (I), then remove

ring (6).

4. Remove swivel shaft (7) from rotor (1). CWPO6606

+ Using too T, remove it.

5. Remove 7 slip seals (8) from rotor (1).

6. Remove backup ring (9) and O-ring (10) from ro-

tor (1).

7. Remove dust seal (11) from swivel shaft (7).

8. Remove 4 plugs (12) and 3 plugs (13) from swivel

shaft (7).

9. Remove pin (14) from swivel shaft (7).

CWPO6607

ASSEMBLY OF CENTER SWIVEL

JOINT ASSEMBLY
PCSOMRX

a Clean it carefully, not to enter the dust.

1. Install pin (14) to swivel shaft (7).

2. Install 4 plugs (12) and 3 plugs (13) to swivel shaft

(7).
* Remove all oil and grease from the plug
thread, then install it.

QK Plug(13):16.7~2.9Nm{1.7f0.3kgmI

& Plug (13), (12) : Tread tightener (LG-5)

Ir Make sure that the plug is lower than shaft

surface, after install plug (13).

w Plug (12) :
32.0 ?I 13.0 Nm I3.3 + 1.3 kgm1

3. Install dust seal (11) to swivel shaft (7).

& Lip of dust seal and rotor, shaft contact face

: Grease (G2-Lll

30-48 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

4. Install backup ring (9) and O-ring (IO) to rotor (I).

Ir Be careful not to damage the O-ring (IO) when
installing. IO

5. Install 7 slip seals (8) to rotor (I).

I
6. Install swivel shaft (7) to rotor (I).
+ After assembled, stand up the swivel joint (7)
end face to under.

7. Install snap ring (6) to rotor (l), then secure with 8

snap ring (5). CWPO6607

8. Install O-ring (4) to rotor (I).

9. Set cover (3) to rotor (I), then tighten 4 mounting

bolts (2).

Q~FI Mounting bolt :

66.0 + 7.0 Nm I6.7 + 0.7 kgm)

PC27 - 45MRX- 1 30-49

0
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

DISASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

1. Remove plate (I).

2. Using snap ring pliers, remove snap ring (2).

3. Remove spacer (3).

4. Using tool T, pull out shaft (4) from rotor (5).

5. Remove dust seal (6) from shaft (4).

6. Remove 4 plugs (7) and 1 plug (8) from shaft (4).

7. Remove 8 slipper seals (9) from rotor (5).

ASSEMBLY OF CENTER SWIVEL

JOINT ASSEMBLY
CKP03107
PC35MRX, PC40MRX, PC45MRX

1. Install 8 slipper seals (9) and O-ring to rotor (5).

2. install 4 plugs (7) and (8) to shaft (4).

* Remove all oil and grease from the plug
thread, then dry the thread.

m Plug (8) : 16.7 + 2.9 Nm Il.72 0.3 kgml

Plug (7) : 32 f. 13 Nm I3.3 + 1.3 kgm}

3. Install dust seal (6) to rotor (5).

4. Install shaft (4) to rotor (5).

* Before installing, coat the dust seal lip and CLPO3108
contact surface and rotor and shaft with
grease (G2-Ll).
* Tap the rotor with a plastic hammer and be
careful not to damage the O-ring when install-
ing.

5. Install spacer (3).

6. Using snap ring pliers, install snap ring.

7. Fit O-ring and install plate (1).

m Mounting bolt :
66.0 + 7.0 Nm (6.7 f 0.7 kgml

30-50 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

REMOVAL OF TRAVEL MOTOR

ASSEMBLY
g Stop the machine on the horizontal ground, then
lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.
A . Drsconnect the cable from the negative (-1 ter-
minal of the battery.
1. Remove sprocket. For details, see REMOVAL OF
CWPO6448
SPROCKET ASSEMBLY.
2. Remove cover (I).
3. Disconnect drain hose (31, travel speed selector
hose (2), and hoses for travel forward, reverse (4),
* Fit a blind plug in the drain hose.
* After disconnecting the hoses, fit tags to dis-
tinguish them.
4. Remove mounting bolt (61, Lifting the travel mo-
tor temporarily. m
5. Lift off travel motor assembly (7).

&I kg Travel motor assembly :

40 kg (PC27MRX. PC30MRX)
50 kg (PC35MX)
60 kg (PC40MRX)
70 kg (PC45MRX)

INSTALLATION OF TRAVEL
MOTOR ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

,$& Thread of travel motor assembly mount-

ing bolt : Thread tightener (LT-2)

m Travel motor assembly mounting bolt CWPO6450

(PC27MRX, PC30MRX, PC35MRX) :
98.0 - 122.5 Nm (IO.0 - 12.5 kgm1

m Travel motor assembly mounting bolt

(PC40MRX, PC45MRX) :
156.8 - 196 Nm {IS.0 - 20.0 kgm)

l Bleeding air
Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.

l Refilling with oil (hydraulic tank)

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.

w Filler plug (PC35MRX) :

181.3 - 240.1 Nm t18.5 - 24.5 kgml

PC27 - 45MRX- 1 30-5 1

a
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

DISASSEMBLY AND ASSEMBLY

OF TRAVEL MOTOR
PHV-500 (FOR PC40MRX-1)

PROCEDURE FOR DISASSEMBLY AND ASSEMBLY

When carrying out disassembly and assembly, wash
all parts thoroughly in flushing oil and be careful not
to let any dirt get in. If dirt gets between assembly
parts, it will cause seizure. Handle the parts with care
and be careful not to scratch or damage them.
The following is an explanation of the procedure for
assembling the travel motor. The disassembly pro-
cedure is in the opposite order. Note that the parts
(bearings, pins) which are press fitted can basically
not be disassembled.
The travel motor consists of 3 blocks as shown in the
diagram below; each block is explained in turn.

Hydraulic Hydraulic Reduction

valve motor gear

I
I I I I I

30-51-I PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

Fit ball, spring, spring holder, and O-ring to plug,

then assemble plug to body (1).

w Plug: 12 - 13 Nm (1.2 - 1.3 kgm)

(Width across flats: 5 mm)

DWP02129

Fit spool assembly, ring, spring, and O-ring to

plug, then assemble plug to body (1).
* The spool assembly cannot be disassembled.
* When fixing body (1) in a vice, use an alumi-
num sheet to protect it.

N Plug: 196 - 245 Nm (20 - 25 kgm)

(Width across flats: 36 mm)

- I \' DWPO2131

Fit spacer, spool, sprrng, anu w-ring to plug, then

assemble plug to body (1).

m Plug: 46 - 51 Nm {4.7 - 5.3 kgm}

(Width across flats: 8 mm)

I / I \ DWP02132

PC27 - 45MRX-1 30-51-2

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

DWP02134

4. Press fit bearing and spring pin to body (1).

Bearing

DWP02136 1

5. Install 2 O-rings to body (1).

I DWP02136 1

30-51-3 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

6. Press fit oil seal to body (2).

2
* Fill the lip of the oil seal with grease.
j, Press fit in the direction shown in the diagram.

Oil seal

DWP02137 1

7. Fit O-ring to body (2), then tighten plug.

m Plug: 12 - 13 Nm (1.2 - 1.3 kgml

@Vidth across flats: 5 mm)
Upper
/

DWP02138

8. Assemble parallel pin to body (2).

DWP02139

9. Press fit bearing to shaft. Bearing

DWPO2140

PC27 - 45MRX-1 30-51-4

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

10. Assemble shaft to body (2).

* Be careful not to let the shaft damage the oil
seal.

11. Assemble control piston to to body (2).

12. Assemble ball and swash plate to body (2).

/ DWPO2144

30-51-5 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

13. Assemble retainer, spring, and retainer in turn to

CYI inder
cylinder barrel, then secure with snap ring.
barrel Spring Snap ring

Retainer

DWPO2145

14. Assemble pin, barrel holder, piston/shoe in turn

to shoe holder, then assemble shoe holder to cyl-
inder barrel to make cylinder barrel assembly.

DWP02147 1

Barrel holder

I DWP02148 1

PC27 - 45MRX-1 30-51-6

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

OWPO2149 1

15. Assemble cylinder barrel assembly to body (2).

16. Fill inside of body (2) with oil (approx. 200 cc).

17. Assemble valve plate to body (I), then fit to body

,_.
(2).
* Coat both faces of the valve plate with grease
to prevent it from falling.

DWPO2151

30-51-7 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

18. Tighten with hexagon socket head bolt.

m Bolt (MIO): 51 - 65 Nm (5.2 - 6.6 kgm)

(Width across flats: 8 mm)
* When fixing the motor in a vice, use an alu-
minum sheet to protect the body.

19. Assemble bearing, snap ring for hole, and bear-

ing in turn to body.
* Press fit the bearing so that the thick inner
race is on the outside compared with the snap
ring.

PC27 - 45MRX-1 30-51-8

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

20. Assemble floating seal and O-ring assembly to Floating

body.
* If it is difficult to assemble, coat the O-ring
with grease.

DWPO2157

21. Assemble floating seal and O-ring assembly to

hydraulic motor.
* If it is difficult to assemble, coat the O-ring
with grease.

DWP02158

22. Assemble hydraulic motor to body, then secure

with snap ring.
1) Remove all oil and grease from seat surface
of floating seal.
2) If it is difficult to insert in the body, use a plas-
tic hammer to tap uniformly around the cir-
cumference of the body to insert.
3) Use tool @or a hydraulic press to tighten the
reduction gear flange and hydraulic motor
flange, then install the snap ring.
4) Adjust the thickness of the snap ring to ad-
just the preload of the bearing. OWPO2159

// DWP02160

30-51-9 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

23. Press fit needle ring to gear Bl.

Needle

DWP0216

24. Assemble needle.

-Sr After assembling, coat with grease to prevent Need
it from coming out.

DWPO2162

25. Press fit needle ring and make gear Bl assembly.

Needle rinu
Gear B 1

DWP02163

26. Assemble thrust washer, gear Bl assembly, thrust

washer, and pin Bl in turn to No.1 carrier, then
press fit spring pin to make No.1 carrier assem-
bly.

No. I carrier

PC27 - 45MRX-1 30-51-10

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

DWP02165

27. Press fit pin b2 and spring pin to No.2 carrier.

DWP02166

28. Assemble gear Sl to No.2 carrier, then secure with

snap ring.

DWPO2167

Snap rina

30-51-11 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

29. Assemble thrust washer, gear B2, needle, and

thrust washer in turn to No.2 carrier, then secure
with snap ring to make No.2 carrier assembly.
Thrust washer

Gear 82

172

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

30. Assemble No.1 carrier assembly to body.

* Assemble so that the spline of No.1 carrier
meshes with the spline of the body.

31. Assemble thrust washer and No.2 carrier in turn

to body.

32. Assemble gear S2. \ Ge8.rS2

DWPO2176

30-51-13 PC27 - 45MRX-1

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

33. Fit O-ring to body.

34. Fill with 800 cc of lubricating oil.

I DWPO2178

35. Assemble thrust ring to cover.

* Coat with grease to hold in position.

Thrust
ring

DWP02179

36. Assemble cover to body.

1) Coat the O-ring with grease, assemble hori-
zontally, and be careful not to damage it.
2) Align the tap holes (G3/8) at the top and bot-
tom with the notches in the body when as-
sembling.

DWP02180

PC27 - 45MRX-1 30-51-14

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

37. Assemble snap ring and secure cover.

* Put a flat-headed screwdriver in contact with
the end face of the snap ring and tap in the
direction of the circumference to install.

38. Fit O-ring to plug (G318) with flange, then tighten.

m Plug: 46 - 51 Nm (4.7 - 5.2 kgm)

(Width across flats: 8 mm)

DWPOPI 82

39. Fit O-ring to plug (G1/8) with flange, then tighten.

Plug with
flange I I
w Plug: 12-13Nm{1.2-1.3kgm)
(Width across flats: 5 mm)

30-51-15 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SPROCKET

REMOVAL OF SPROCKET
ASSEMBLY
1. Remove track shoe assembly.

2. Remove mounting bolts, and pull out sprocket (1)

slightly. m
* Jack up machine with work equipment, then
set block between track frame and track shoe.

INSTALLATION OF SPROCKET
ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

& Thread of sprocket assembly mounting

bolt : Thread tightener (LT-2)

w Sprocket assembly mounting bolt

(PC27MRX, PC30MRX, PC35MRX) :
98.0 - 122.5 Nm (10.0 - 12.5 kgm}

m Sprocket assembly mounting bolt

(PC40MRX, PC45MRX) :
156.8 - 196 Nm (16.0 - 20.0 kgm)

30-52 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

REMOVAL OF SWING MOTOR,

SWING MACHINERY ASSEMBLY
PC27MRX, PC30MRX
A Stop the machine on the horizontal ground, then
lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit and hvdraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove handrail (I).

2. Remove floor mat, then remove travel speed se-
lector switch (2) from floor.
* Disconnect wiring connector LS3) for travel
speed selector switch.
3. Remove floor (3).
4. Disconnect hose (4) to hydraulic tank.
5. Disconnect hose (5) (left swing) and hose (6) (right
swing) from main valve.
6. Disconnect hose (7) from main valve (S hose).
7. Disconnect brake release hose (8).
8. Remove 6 mounting bolts (9). m
9. Using forcing bolt 0, disconnect swing machin-
ery and swing motor assembly from revolving
frame.
10. Remove swing machinery and swing motor as-
sembly (IO).

&I kll Swing machinery and swing motor assembly

: 40 kg

INSTALLATION OF SWING
MOTOR, SWING MACHINERY
ASSEMBLY
PC27MRX, PC30MRX
l Carry out installation in the reverse order to re-
moval.
/ CWPO6645

& Thread of swing machinery and swing mo-

tor assembly mounting bolt :
Thread tightener (LT-2)

m Swing machinery and swing motor assem-

bly mounting bolt :
110.3 k 12.3 Nm Ill.3 - 1.3 kgm)

l Refilling with oil (hydraulic tank)

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.

l Bleeding air
Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX-1 30-53

a
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

REMOVAL OF SWING MOTOR,

SWING MACHINERY ASSEMBLY
PC35MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove operator cabin assembly. For details, see

REMOVAL OF OPERATOR’S CAB ASSEMBLY
* Operator’s cab specification only

2. Remove canopy assembly. For details, see RE-

MOVAL OF CANOPY ASSEMBLY.
* Canopy specification only

3. Remove handrail, travel speed selector switch

and floor plate.
* Disconnect wiring connector (53) for travel
speed selector switch.

4. Remove wiring connector (I) (MIO), (2) (M8) and

(3)(M9), then move to main control side.

5. Disconnect cylinder hose (4).

Sr Breaker specification only

6. Disconnect 6 hoses (5) from swing motor and

swing machinery assembly.
* Fit a blind plug in the drain hose.
* After disconnecting the hoses, fit tags to dis-
tinguish them.

7. Using forcing bolt, disconnect swing machinery

and swing motor assembly from revolving frame.

8. Liftoff swing machinery and swing motor assem-

bly (6). a

r+ kg Swing machinery and swing motorassembly

: 40 kg

30-54 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

INSTALLATION OF SWING
MOTOR, SWING MACHINERY
ASSEMBLY
PC35MRX

l Carry out installation in the reverse order to re-

moval.

w Swing machinen/ and swing motor assem-

bly mounting bolt :
98 - 123 Nm (IO - 12.5 kgm)

Refilling with oil (hydraulic tank)

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.

w Filler plug :
181.3 - 240.1 Nm 118.5 - 12.5 kgm}

Bleeding air
Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-55

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

REMOVAL OF SWING MOTOR,

SWING MACHINERY ASSEMBLY
PC4OMRX, PC45MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove operator cabin assembly. For details, see

REMOVAL OF OPERATOR’S CAB ASSEMBLY.
Ir Operator’s cab specification only

2. Remove canopy assembly. For details, see RE-

MOVAL OF CANOPY ASSEMBLY.
* Canopy specification only

3. Remove swing motor upper cover.

4. Remove floor frame left cover.

5. Remove boom swing control pedal, then place it

side.

6. Disconnect travel lever cable (I) at lever side. m

* Disconnecttravel levercablefrom floorframe
also.
* Make sure the mounting dimension before
disconnection.

7. Disconnect 6 hoses (2) from swing motor and

swing machinery assembly.
Ir Fit a blind plug in the drain hose.
* After disconnecting the hoses, fit tags to dis-
tinguish them.

8. Using forcing bolt 0, disconnect swing machin-

ery and swing motor assembly from revolving
frame.

9. Lift off swing machinery and swing motor assem-

bly (3). m

&I kg Swing machinery and swing motor assembly

: 50 kg

30-56 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

INSTALLATION OF SWING
MOTOR, SWING MACHINERY
ASSEMBLY
PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

* Adjust the control lever and pedal. For details,

see TESTING AND ADJUSTING, Testing and
adjusting the control lever and pedal .

w Swing machinery and swing motor assem-

bly mounting bolt :
98 - 123 Nm {IO - 12.5 kgm)

l Refilling with oil (hydraulic tank)

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.

l Bleeding air
Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-57

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

DISASSEMBLY OF SWING
MOTOR, SWING MACHINERY
ASSEMBLY
There is no oil drain plug installed, so prepare an
oil container to catch the oil inside the case, and
drain the oil during the disassembly process.

- : Swing motor, swing machinery case :

approx. 0.9 e
(&27MRX, PC30MRX, PC35MRX)
approx. 1.3 L?(PC4OMRX, PC45MRX)

1. Preparatory work CLPO.2665

Set swing motor and swing machinery assembly

on block 0.

2. Swing motor assembly

Remove swing motor assembly (1).

3. Ring gear
Remove ring gear (2).

4. No. 1 sun gear

Remove No. 1 sun gear (3).

5. No. 1 planetary carrier assembly

1) Remove No. 1 planetary carrier assembly (4).
2) Disassemble No. 1 planetary carrier assem-
bly as follows.
i) Using snap ring pliers, remove 3 snap
rings (5).
ii) Remove 3 thrust washers (6).
iii) Remove 3 planet gears (7).
iv) Remove 3 needle bearings (8).
v) Remove 3 thrust washers (9).
vi) Remove thrust plate (IO).
vii) Knock pins into shafts, then remove 3
shafts (11) from carrier (12).
* After removing the shafts, remove the
pins from the shafts.
CLPO2688 CLPO7.669

CLPO2690 CLP02691

30-58 PC27 - 45MRX- 1

a
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

6. No. 2 sun gear

1) Remove No. 2 sun gear (13).
2) Using snap ring pliers, remove snap ring (14)
from-sun gear (13).

7. No. 2 planetary carrier assembly

1) Remove No. 2 planetary carrier assembly (15).

14
CLP02692 CLP02693

2) Disassemble No. 2 planetary carrier assem-

bly as follows.
i) Using snap ring pliers, remove 3 snap
rings (16).
ii) Remove 3 thrust washers (17).
iii) Remove 3 planet gears (18).
iv) Remove 3 needle bearings (19).

I9 18
CLP02694 CLP02695

v) Remove 3 thrust washers (20).

vi) Remove thrust plate (21).
vii) Knock pins into shafts, then remove 3
shafts (22) from carrier (23).
* After removing the shafts, remove the
pins from the shafts.

CLP02696 CLP02697

8. Output shaft assembly

1) Remove 2 spacers (24).
2) Using push tool 0, pull out output shaft as-
sembly (25).

CLP02696 CKP02699

PC27 - 45MRX- 1 30-59

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

3) Disassemble output shaft assembly as fol-

lows.
i) Remove bearing inner race (26) from shaft
(27).
ii) Remove seal (28).

9. Case assembly
1) Remove bearing inner race (29) from case as-
sembly (30).

CLPO2700 CLPO2701

2) Disassemble case assembly as follows.

i) Remove bearing outer race (31) from case
assembly (32).
ii) Remove bearing outer race (33).
iii) Remove oil seal (34).

CLPO2702 CLPO2703

30-60 PC27 - 45MRX- 1

a
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

ASSEMBLY OF SWING MOTOR,

SWING MACHINERY ASSEMBLY
1. Case assembly
Assemble case assembly as follows.
1) Using tool Fl, press fit oil seal (34) to case
(32).
* When press fitting the oil seal, set with
the rubber surface at the bottom and the
metal surface at the top.
,+& Press fitting face of the oil seal :
Gasket sealant (LG-6)
* When coating, be careful not to get CKP02704
any gasket sealant on oil seal lip or
shaft.
& Fill 40 - 60% of the space at the oil
seal lip with grease (G2-LI).

2) Using tools F2 and F3, press fit bearing outer

races (33) and (31) to case (32).

2. Output shaft assembly

1) Assemble output shaft assembly as follows.
i) Install seal (28) to shaft (27).
* Install the seal with the lip at the top.
ii) Using tool F4, press fit bearing inner race
(26) to shaft (27).
CKP02705

2) Set case assembly (30) to shaft assembly (25).

& Coat the rolling surface of the bearing
inner race, the track surface, and the
seal lip with approx. 40 g of grease (G2-
LI).
. PC27MRX, PC30MRX, PC35MRX :
Approx. 40 g
PC40MRX, PC45MRX :
Approx. 60 g

3) Using tool F5, press fit bearing inner race (29).

* Press-fitting force :
Max. 11,170 N{Max. 1140 kg)
(PC27MRX, PC30MRX, PC35MRX) CKPOZ 706

Max. 13,300 NIMax. 1360 kg)

(PC40MRX, PC45MRX)
Ir Press fit the bearing inner race gradually
while rotating the case.

4) Install spacer (24).

* After installing, set the case and output
shaft assembly on top of the block.

CLPO2707

PC27 - 45MRX-1 30-61

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

5) Using tool F6, measure starting torque of out-

put shaft.
* Starting torque :
Max. 13.2 Nm {Max. 1.35 kgm}

CLPO2706
I

3. No. 2 planetary carrier assembly

1) Assemble No. 2 planetary carrier as follows.
i) Set 3 shafts (22) to carrier (23), and knock
in pins.
* After press fitting the pins, caulk the
carrier portion at 2 places around the
pin holes.
ii) Install thrust plate (21).
iii) Install 3 thrust washers (20).

CLPO2697 CLP0269E

iv) Install 3 needle bearings (19).

v) Install 3 planet gears (18).
vi) Install 3 thrust washers (17).
vii) Using snap ring pliers, install 3 snap rings
(16).
* Use new snap rings.
Ir When installing the snap ring, do not
open the end gap more than 7 mm.

2) Install No. 2 planetary carrier assembly (15).

19 I8
CLP02695 CLP02694

4. No. 2 sun gear

1) Using snap ring pliers, install snap ring (14)
to sun gear (13).
2) Install No. 2 sun gear (13).
* nstall with the longer dimension from the
snap ring at the bottom.

I4
CLPO2692 CLPO2693

30-62 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY

5. No. 1 planetary carrier assembly

1) Assemble No. 1 planetary carrier as follows.
II
i) Set 3 shafts (11) to carrier (12), and knock
in pins.
* After press fitting the pins, caulk the
carrier portion at 2 places around the
pin holes.
ii) Install thrust plate (10).
iii) Install 3 thrust washers (9).

12

CLPO2691 CLPO2690

iv) Install 3 needle bearings (8).

v) Install 3 planet gears (7).
vi) Install 3 thrust washers (6).
vii) Using snap ring pliers, install 3 snap rings
(5).
* Use new snap rings.
* When installing the snap ring, do not
open the end gap more than 7 mm.

2) Install No. 1 planetary carrier assembly (4). 6 5

6. No. 1 sun gear CLPO2689 CLPO2668
Install No. 1 sun gear (3).

7. Ring gear
Install ring gear (2).

a Case mating surface : Gasket sealant (LG-4)

QFI Mounting bolt :

59.0 - 71.0 Nm (6.0 - 7.5 kgm)
(PC27MRX. PC30MRX, PC35MRX)
98 - 123 Nm {IO - 12.5 kgm)
(PC40MRX, PC45MRX)

8. Refilling with oil

Fill case with engine oil.

Case : Approx. 0.9 e (EOIO-CD)

(PC27MRX, PC30MRX, PC35MRX)
Approx. 1.3 e (EOlO-CD)
(PC40MRX, PC45MRX)

9. Swing motor assembly

Fit O-ring and install swing motor assembly (1).

w Mounting bolt :
65 f 6 Nm I6.75 Itr 0.75 kgm)
(PC27MRX, PCSOMRX, PC35MRX)
98 - 123 Nm {IO - 12.5 kgm)
(PC40MRX, PC45MRX)
CLPO2665

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY SWING MOTOR

DISASSEMBLY OF SWING
MOTOR ASSEMBLY
LMFl6AB

1. Installation of repair stand

1) Remove the 4 swash plate mounting bolts and
install tool PI-4 to the swing motor assembly.

DVP01713

2) Set swing motor assembly (1) to tool PI.

2. Safety valve, hydraulic timer valve, check valves,

and plugs
1) Remove safety valve (2).
2) Remove plug (3), spring (4), and hydraulic
timer valve (5).
3) Remove plugs (6), springs (7), and check
valves (8).
4) Remove plug (9).
* The following works can be done even if
this work is not performed.

CUP06304

30-63-I PC27 - 45MRX-I

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DISASSEMBLY AND ASSEMBLY SWING MOTOR

Swash plate and shaft assembly

Loosen the mounting bolts diagonally and evenly
and remove swash plate and shaft assembly (10).
* The spacer and thrust plate are sticking to the
rear side of the swash plate and they are re-
moved together with the swash plate. Take
care not to drop them.
* The washers and filters may be sticking to the
brake spring holes of the swash plate. Take
care not to drop them.

CUP06305

Spacer and thrust plate

Remove spacer (11) and thrust plate (12) from the
swash plate and shaft assembly.
* The thrust plate has a front side and rear side.
Check its direction when removing.
* The installation method ofthe spacer depends
on its material.
Steel spacer: Press fit
Copper alloy spacer: Clearance fit

CUP06306

Shaft assembly
Remove snap ring (13) and then remove shaft as-
sembly (14) from swash plate (15).

Disassembly of shaft assembly

Remove main bearing (16) from shaft (17) with
push tool 0.

CUP06308

PC27 - 45MRX-1 30-63-Z

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

Brake springs
Remove brake springs (18) (12 pieces).
* Washer (19) and filter (20) installed to the ,_
swash plate are on only one spring. Check
the position of that spring.

Shoe retainer and piston assembly

1) Pull shoe retainer and piston assembly (21)
out of the cylinder block.
2) Pull pistons (22) out of shoe retainer (23).

i3

CUP06310 CUP06311

8. Retainer guide
Remove retainer guide (24).

9. Preload pins
Remove preload pins (25) (3 pieces).

CUP06312

10. Brake piston

Apply air pressure to port B through tool P2 gradu-
ally to remove brake piston (26).
* When applying air pressure, hold the brake
piston with a cloth, etc. so that it will notjump
out.

30-63-3 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

l Disassembly of brake piston

Remove O-rings (27) and backup rings (28) from
the brake piston.

CUP06315

11. Piston
Remove piston (29) and spring (30) from the mo-
tor housing.

12. Cylinder block assembly

Remove cylinder block assembly (31) from the
motor housing.

CUP06317

l Disassembly of cylinder block assembly

Set tool P3 to the cylinder block.
Securing the bolt of P3 with a wrench, etc.,
tighten the nut to compress spring (33) and
remove snap ring (34).
Loosen the nut of tool P3 gradually to release
the spring tension and remove tool P3.
Remove washer (35), spring (33), and washer
(36) from cylinder block (32).

I,
DVPO1716

PC27 - 45MRX-1 30-63-4

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

13. Plates and discs

1) Remove snap ring (37).
2) Remove plates (38) and discs (39).
j, The numbers of the plates and discs are 4
and 3 respectively.
j, Do not clean the discs with solvent or blow
air against them strongly.

CUP06320

14. Valve plate

Remove valve plate (40).
* When reusing the valve plate, keep it, taking
care not to damage its contact face against
the cylinder block.

15. Sub-bearing
Remove sub-bearing (41) from the motor hous-
ing.

30-63-5 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

ASSEMBLY OF SWING MOTOR

ASSEMBLY
LMFl6AB
* Clean the parts carefully. In particular, remove all
foreign matter from holes and oil passages.
* Check that the parts are free from burrs.
* Apply engine oil (New oil of EOIO-CD) to the ro-
tary parts and sliding parts before assembling.
* Check the following parts for contact before as-
sembling, referring to “Check of contact of each
part”.
l Motor housing and valve plate

1. Sub-bearing
Press fit sub-bearing (41) with tool P4 until it is
fitted to the bottom of the motor housing.
* Press fitting load: Max. 833 N (85 kg}

& Press fitting surface of bearing:

Engine oil (EOIO-CD)

r DVP01717

2. Valve plate
Install valve plate (40).
* Match pin hole b of the valve plate to pin a on
the motor housing side.
* When installing the valve plate, take care that
it will not interfere with the pin and sub-bear-
ing on the motor housing side.

3. Guide (Tool P5)

Set tool P5 to the inner race hole of sub-bearing
(41).
* Do not pull out tool P5 until the shaft assem-
bly is installed.

PC27 - 45MRX-1 30-63-6

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DISASSEMBLY AND ASSEMBLY SWING MOTOR

4. Cylinder block assembly

l Assembly of cylinder block assembly
1) Install washer (36), spring (33), and washer
(35) to cylinder block assembly (32).
2) Set tool P3 to the cylinder block assembly.
3) Securing the bolt of tool P3, tighten the nut to
compress spring (33) and install snap ring (34).
* Check that the snap ring is fitted to the
mounting groove securely.
4) Remove tool P3.
II
DVPOl

5) Install 3 preload pins (25) to the shaft hole of

the cylinder block.
* Apply grease (G2-LI) to the preload pins
before installing them so that theywill not
come off the mounting grooves.

CUP06326

l Installation of cylinder block assembly

Install cylinder block assembly (31) to the motor
housing.
* Check that 3 preload pins (25) have not come
off.

CUP06327
5. Plates and discs
1) Install plates (38) and discs (39).
* Install the plates and discs alternately.
(Plates: 4 pieces, discs: 3 pieces)

& Disc surface: Engine oil (EOIO-CD)

* When installing each plate, match its out-

side projection to the inside groove of the
motor housing.
* When installing each disc, match its in-
side projection to the outside groove of
the cylinder block.
2) Install snap ring (37).
* Check that the snap ring is fitted to the
mounting groove securely.

30-63-7 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

Piston
Install spring (30) and piston (29) to the motor
housing.

Brake piston
Assembly of brake piston
Install O-rings (27) and backup rings (28) to the
brake piston.
* Install the backup rings as shown in the fig-
ure.

I CUP06315

Installation of brake piston

Install brake piston (26) to the motor housing.
* Install the brake piston straight so that the O-
rings and backup rings will not be damaged.

Retainer guide
Install retainer guide (24).
* After installing the retainer guide, match the
spline to the cylinder block.

LJ CUP06330

PC27 - 45MRX-1 30-63-8

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

9. Shoe retainer and piston assembly

1) Install piston (22) to shoe retainer (23).
2) Install shoe retainer and piston assembly (21)
to the cylinder block.

CUP06345

10. Spacer and thrust plate

Install spacer (11) and thrust plate (12) to the
swash plate.
* The installation method of the spacer depends
on its material.
Steel spacer: Press fit
Copper alloy spacer: Clearance fit
* Press fit steel spacer with tool P6 until it is
fitted to the swash plate.
* Press fitting load: Max. 980 N {IO0 kg}

& Press fitting surface:

CUP06332
Engine oil (EOIO-CD)

* Judge the direction of the thrust plate by the

difference of the surface machining accuracy
and the sectional shape and install it as shown
in the figure.

Swash
I
plate side

DVP01719

11. Filter and brake spring

1) Install filter (20) and washer (19) to the swash
plate.
* Turn over the swash plate and find out the
through spring hole and install the filter
to that hole.
2) Install 12 brake springs (18) to the swash plate.

I - CUP06331

30-63-g PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

12. Swash plate

1) Turn tool PI to bring the opening of the mo-
tor housing to the side.
2) Install swash plate (15) to the motor housing
and tighten the mounting bolt temporarily.

& Mating face of motor housing:

Gasket sealant (LGd/LG-7)

* Take care that the O-ring will not be

caught.
* Tighten the mounting bolt to the specified
torque after the shaft assembly is in-
stalled.

13. Shaft assembly

. Assembly of shaft assembly
Press fit bearinq (16) to shaft (17) with tool P7. P7
* Set the bea;ng so that the shield side will be
on the outside of the shaft.
* Apply tool P7 to the inner race of the bearing
securely and press fit the bearing until it is
fitted to the shaft end.
* When press fitting the bearing, take care not
to damage the shield.
* Press fitting load: 0.34 - 1.67 kN (35 - 170 kg}

& Press fitting surface of bearing:

Engine oil (EOIO-CD)

. Installation of shaft assembly

1) Turn tool PI to direct the swash plate up.
2) Pull tool P5 out of the swing motor assembly.
3) Install shaft assembly (14) and secure it with
snap ring (13).
* Check that the snap ring is fitted to the
mounting groove securely.
4) Tighten the swash plate mounting bolts to the
specified torque.

w Mounting bolt:
98.1 - 122.7 Nm {IO - 12.5 kgm)

PC27 - 45MRX-1 30-63-I 0

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

14. Safety valve, hydraulic timer valve, check valves,

and plugs
1) Fit the O-ring and install plug (9).

& Plug: Adhesive (LOCTITE 638/648)

m Plug: 14.7 - 24.5 Nm {I.5 - 2.5 kgm)

2) Install checkvalves (8) and springs (7). Fit the

O-rings and install plugs (6).

& Plug: Adhesive (LOCTITE 638/648)

w Plug: 44.1 - 63.7 Nm (4.5 - 6.5 kgm)

3) Install hydraulic timer valve (5) and spring (4).

Fit the O-ring and install plug (3).

& Plug: Adhesive (LOCTITE 638/648)

m Plug: 14.7 - 24.5 Nm (1.5 - 2.5 kgm)

4) Fit the O-ring and backup ring and install

safety valve (2).

m Safety valve: 49.1 - 58.9 Nm (5 - 6 kgm)

108 - 142 Nm {II -i4.5 kimj
(Only PC5OUU-2)

* Apply 2 drops (about 0.04 g) of adhesive

to a part 2 - 3 mm from each screw end of
CUP06304
plugs (3), (6), and (9).
* Clean the threads of the above plugs and
the mating female screw holes and then
degrease and dry them.
* After tightening the above plugs, do not
apply pressure for 30 minutes.

15. Check of turning torque

1) Referring to the figure, assemble tool P8.
2) Set tool P9 to the shaft end.
3) Install tool P8 to port B and apply hydraulic
pressure to release the brake.
* Brake releasing pressure:
2.9 f 0.3 MPa (30 f 3 kg/cm2}
Pa-9 Pa-6 Pa-2 Pa-1 DVP0,7
4) Turn the shaft at a constant speed of 3 - 5 secl
turn and measure the turning torque.
* Standard turning torque:
4.9 - 9.8 Nm {0.5 - 1 .O kgm}
* Fluctuation of turning torque:
Max. 1.96 Nm {Max. 0.2 kgm}
* Prepare a pan to receive oil which flows
out through the shaft and filter when the
turning torque is measured.

DVP01723

30-63-11 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

16. Port nipples

Fit the O-ring and install each nipple.

m Nipple for port MA (42):

78 - 103 Nm (8 - 10.5 kgm}
Nipple for port MB (43):
78 - 103 Nm (8 - 10.5 kgm}
Nipple for port T (44):
29-39Nm{3-4kgm)
Nipple for port B (45):
29-39Nm(3-4kgm)
Nipple for port S (46):
78 - 103 Nm (8 - 10.5 kgm} CUP06339

PC27 - 45MRX-1 30-63-12

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR

CHECK OF CONTACT OF EACH PART

* If either motor housing or valve plate is replaced
with a spare (new one) or repaired, check their
contact according to the following procedure.
j, If both of the motor housing and valve plate are
replaced with spares (new ones), this check is not
necessary.

Check of contact of motor housing and valve plate

1) Degrease and dry the all parts.
* Do not wipe the parts with cloths, etc. Motor housing
Valve Plate
2) Apply check paint to the motor housing and place
the valve plate on it.
* Apply the paint thinly and evenly.
3) Pressing valve plate against the motor housing
with force of 32.9 - 49.0 N {4 - 5 kgm}, turn the
valve plate by90 degrees and return it 2 - 3 times.
4) Remove the valve plate and transfer the contact is surface, there must
be no ~1s~ and contact
surface onto a tape and check it. must be more then 80%
* Standard contact: Mating faces must not have DVPOi 724
any play and contact area must be more than
80%.

30-63-13 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

REMOVAL OF REVOLVING
FRAME ASSEMBLY
PC27MRX, PC30MRX

a Stop the machine on the horizontal ground.

a Disconnect the cable from the negative (-) ter-

minal of the battery.

1. Remove work equipment assembly. For details,

see REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.
CWPO6546
2. Sling boom cylinder assembly (2), then pull out
pin (I), and remove boom cylinder assembly (2).
a

&I ta Boom cylinder assembly : 25 kg

3. Remove swing motor, swing machinery assem-

bly. For details, see REMOVAL OF SWING MO-
TOR, SWING MACHINERY ASSEMBLY.

4. Disconnect each swivel joint piping, (3) (right

travel motor reverse), (4) (travel speed selector),
(5) (left travel motor forward), (6) (blade cylinder
head side), (7) (left travel motor reverse), (8) (right
travel motor forward), (9) (boom cylinder bottom
side), (IO) (hydraulic tank)
Ir After disconnecting the pipings, fit tags to dis-
tinguish them.

5. Remove clamper bracket (I I). m

6. Disconnect grease hose from revolving frame,

then remove elbow.

7. Sling revolving frame assembly (13) temporarily,

then pull out mounting bolt. m
Sr Remain 2 bolts at front and rear
6

8. Remove remaining bolts, then sling out revolv- \ cwPo664e

ing frame assembly (13).

* Using a lever block, adjust the balance of the
revolving frame to the front, rear, left and
right, then remove remaining mounting bolts,
and lift off.
Ir Be careful not to hit the swivel joint when re-
moving.

&I kg Revolving frame assembly :

1,100 kg (PC27MRXI
1,300 kg (PC30MRX)

CWP0654

30-64 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

INSTALLATION OF REVOLVING
FRAME ASSEMBLY
PC27MRX, PC30MRX

• Carry out installation in the reverse order to re-

moval.

1
¤ When aligning the position of the pin hole,
never insert your fingers in the pin hole.
fl Insert shim without fail.

2
8 Clamper bracket mounting bolt :
Thread tightener (LT-2)
9 Clamper bracket mounting bolt :
98.0 – 122.5 Nm {10.0 – 12.5 kgm}

3
8 Revolving frame assembly mounting bolt :
Thread tightener (LT-2)
9 Revolving frame assembly mounting bolt :
117.7 – 137.3 Nm {12.0 – 14.0 kgm}

• Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

• Bleeding air
Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.

PC27 – 45MRX-1 30-65

1
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

REMOVAL OF REVOLVING
FRAME ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

¤ Stop the machine on the horizontal ground.

¤ Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Remove work equipment assembly. For details,

see REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.
2. Disconnect 2 hoses, then remove pin (1) and lift
off boom cylinder assembly (2). 1
fl Make sure shim thickness and quantity, when
removed the boom cylinder.
0 Boom cylinder assembly :
35 kg (PC35MRX)
45 kg (PC40MRX, PC45MRX)
3. Remove floor frame assembly. For details, see RE-
MOVAL OF FLOOR FRAME ASSEMBLY.
(PC40MRX, PC45MRX)
4. Remove swing motor, swing machinery assem-
bly. For details, see REMOVAL OF SWING MO-
TOR, SWING MACHINERY ASSEMBLY.
(PC40MRX, PC45MRX)
5. Disconnect hoses from center swivel joint, shown
under.
• Right travel motor hose (3), (4)
• Left travel motor hose (5), (6)
• Travel speed selector hose (7)
• Blade cylinder head side hose (8)
• Boom cylinder bottom side (9)
• Travel motor drain hose (10)
fl Fit a blind plug in disconnected hoses.
fl After disconnecting the hoses, fit tags to dis-
tinguish them.
6. Remove detect lever (11).
7. Disconnect grease hose from revolving frame,
then remove elbow.
8. Sling revolving frame assembly (12) temporarily
using lifting bolt 1, then pull out mounting
bolt(13). 2
fl Remain 2 bolts at front and rear
9. Remove remaining bolts, then sling out revolv-
ing frame assembly (13).
fl Using a lever block, adjust the balance of the
revolving frame to the front, rear, left and
right, then remove remaining mounting bolts,
and lift off. 3
fl Be careful not to hit the swivel joint when re-
moving.
0 Revolving frame assembly :
1,550 kg (PC35MRX, PC4027MRX)
1,750 kg (PC45MRX)

30-66 PC27 – 45MRX-1

1
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

INSTALLATION OF REVOLVING
FRAME ASSEMBLY
PC35MRX, PWOMRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.

6 Pin, sliding surface when assembling :

CWPO7349
Molybdenum disulphide grease ILM-PI

& Greasing after assembling pin :

Grease (Hyper white grease or equivalent)

+ Adjust the clearance between the bottom of

cylinder (2) and boom swing bracket (12) a
with shim. (PC35MRX)
l Clearance a : Max. 1 mm
l Shim thickness : 1 mm

fi[ fi3j

& Revolving frame mounting bolt :

Thread tightener (LT-2)

w Revolving frame mounting bolt :

98.0 - 122.5 Nm (10.0 - 12.5 kgm}
(Target 112.7 Nm III.5 kgm})

Refilling with oil (hydraulic tank)

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.

w Filler plug (PC35MR) :

181.3 - 240.1 Nm (18.5 - 24.5 kgm}

Bleeding air
Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-67

0
DISASSEMBLY AND ASSEMBLY SWING CIRCLE

REMOVAL OF SWING CIRCLE

ASSEMBLY
1. Remove revolving frame assembly. For details,
see REMOVAL OF REVOLVING FRAME ASSEM-
BLY.

2. Using eyebolts, lift off swing circle assembly (1).

m

&I te Swing circle assembly :

40 kg (PC27MRX, PC30MRX, PC35MX)
60 kg (PC40MRX, PC45MRX)

PC27.30MR
INSTALLATION OF SWING
CIRCLE ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

pJ

Ir nstall so that the soft zone S mark on the in-

ner race is on the left side of the track frame.

& Swing circle assembly mounting bolt :

CUP07327
Thread tightener (LT-2)

m Swing circle assembly mounting bolt :

117.6 - 137.2 Nm (12 - 14 kgm} PC36MR
(Target 127.4 Nm {I3 kgm})
(PC27MRX, PC30MRX)

m Swing circle assembly mounting bolt :

98 - 122.5 Nm {IO - 12.5 kgm)
(Target 112.7 Nm {I 1.5 kgm})
(PC35MRX, PC4OMRX. PC45MRX)

& Face of inner race teeth : Grease (G2-LI)

s CUP07326

PC40.45MR

CUP07328

30-68 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY IDLER

REMOVAL OF IDLER ASSEMBLY

1. Remove track shoe assembly. For details, see RE-
MOVAL OF RUBBER SHOE ASSEMBLY or RE-
MOVAL OF STEEL SHOE ASSEMBLY.

2. Lift off idler assembly (1).

& kg idler assembly :

25 kg (PC27MRX, PC30MRX)
40 kg (PC35MRXl
60 kg (PC40MRX, PC45MRX)

CLPO2719

INSTALLATION OF IDLER
ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

PC27 - 45MRX- 1 30-69

Q
DISASSEMBLY AND ASSEMBLY IDLER

DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove cover (1) and bracket (2).

2. Remove support (3).

3. Remove support and shaft assembly (4).

4. Remove shaft (5) from support (6).

5. Remove floating seal (7) from support (3) and (6).

CKP02979 CKP029BO

6. Remove 2 floating seals (8) from idler (9).

CKP0298I

7. Remove 2 bushings (IO) from idler (9).

CKP02982

30-70 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY IDLER

ASSEMBLY OF IDLER ASSEMBLY

1. Using tool Ll, press fit 2 bushings (IO) to idler
(9).

CKP02983

2. Using tool L2, install 2 floating seals (8) to idler

(9).
* Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
Ir Coat the sliding surface of the floating seal
with engine oil (EOBO-CD) before installing,
and be careful not to let any dirt or dust stick
to it.

CKP029.34
3. Using tool L2, install floating seals (7) to support
(3) and (6).
Ir Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
* Coat the sliding surface of the floating seal
with engine oil (E030-CD) before installing,
and be careful not to let any dirt or dust stick
to it.

4. Fit O-ring and install shaft (5) to support (6).

& Mounting bolt : Thread tighener (LT-2)

5. Install support and shaft assembly (4) to idler.

CKP02935 CKP02979

6. Fill inside of idler with engine oil.

Inside portion of idler :

Approx. 20 cc (E030-CD)

7. Install support (3).

& Mounting bolt : Thread tighener (LT-2)

8. Install bracket (2).

& Mounting bolt : Thread tighener (LT-2)

w Mounting bolt :
110.5 + 12.5 Nm Ill.25 f 1.25 kgm1

9. Install cover (I).

PC27 - 45MRX- 1 30-71

a
DISASSEMBLY AND ASSEMBLY RECOIL SPRING

REMOVAL OF RECOIL SPRING

ASSEMBLY
1. Remove idler assembly. For details, see REMOVAL
OF IDLER ASSEMBLY.

2. Pull out recoil spring assembly (I) and remove.

a

Be careful not to damage the grease fitting

g
when removing.

&I kg Recoil spring assembly : 30 kg (PC35MRX)

t Recoil spring assembly for PC27MRX, CLPO2721
PC30MRX, PC40MRX and PC45MRX are less
than 25 kg.

INSTALLATION OF RECOIL
SPRING ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

w
Sr Install the grease fitting facing the outside of
the chassis.

30-72 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING

DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Piston
1) Remove valve (I ).
2) Remove piston (2).

CKP02981

2. Recoil spring
1) Using tool M, set recoil spring to press.
g The recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.

2) Apply hydraulic pressure slowly to compress

spring, then remove screw (3) and remove nut
(4).
* Compress the spring to a point where the
nut becomes loose.
* Installed load of spring :
kN {kg1
Steel shoe
Model Rubber shoe (Option)
PC27MRX, 28.09 (2,865) -
PC30MRX

PC35MRX 30.9 13,153) 19.7{2,012}

PC40MRX, 42.4{4,326} 26.9I2.7481

PC45MRX

CKP029B7

3) Release the hydraulic pressure slowly and al-

low spring to extend, then remove stopper (5)
and spring (6) from cylinder assembly (7).
* Free length of spring :
248 mm (PC27MRX, PC30MRX)
257 mm (PC35MRX)
362 mm (PC40MRX, PC45MRX) 5

CKP02988

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY RECOIL SPRING

3. Cylinder
1) Remove snap ring (8), then remove spacer (9)
from cylinder.
2) Remove dust seal (I I)
3) Remove O-ring (12).

CKP02989

30-74 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING

ASSEMBLY OF RECOIL SPRING

ASSEMBLY
1. cylinder
1) Install O-ring (12) to cylinder (IO).
2) Install dust seal (1 I).
3) Fit spacer (9) and secure with snap ring (8).

CKP02985

2. Recoil spring
1) Assemble cylinder assembly (71, spring (61,
and stopper (5).

CKP02988

r
2) Using tool M, set recoil spring to press.
A The recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.

3) Apply hydraulic pressure slowly to compress

spring, then fit nut (4) and install screw (3).
* Installed height of spring :
mm
Steel shoe
Model Rubber shoe (Option)
PC27MRX, 206.4 -
PC30MRX

PC35MRX 188 213

PC40MRX, 202.2 238.2

PC45MRX

Ir Installed load of spring :

kN ikal
Steel shoe
Model Rubber shoe (Option)

CKP02987

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY RECOIL SPRING

Sr After assembling the recoil spring, check

that the out-of -parallel between surface
a of cylinder (7) and surface b of stopper
(5) is less than 0.5 mm.

CKP02990

3. Piston
1) Tighten plug (I) temporarily.
* Grease will come out from grease hole c,
so tighten completely, then turn back
approx. 2 turns.
2) Add approx. 120 cc of grease (G2-Ll) inside
cylinder.
3) Assembly cylinder (2) and push in until grease
come out from grease hole c.
4) When grease come out, tighten valve (I).
* After tightening the valve, check that the
grease fitting is facing the outside of the CKP02991
chassis.

30-76 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER

REMOVAL OF TRACK ROLLER

ASSEMBLY
PC27.30MR

1. Loosen valve (I 1to relieve track shoe tension.

If

A The recoil spring cylinder is under extremely

high pressure. Never loosen the valve more
than one turn.
If the grease does not come out easily, move
the machine backwards and forwards.

2. Swing upper structure 90”, then use work equip-

PC36 -40 *46MR
ment to raise track frame (2).
* Raise the blade before raising the track frame. ar

3. Remove track roller assembly (3). m /’

CUP07330

INSTALLATION OF TRACK
ROLLER ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing track shoe tension.

CLP02723

Set track roller assembly for installing posi-

tion, then operate the work equipment con-
trol levers to lower the machine gradually, and
tighten the mounting bolts partially.

& Track roller assembly mounting bolt :

Thread tightener (LT-2)

Operate the work equipment control levers to

lower the machine completely to the ground,
then tighten the mounting bolts fully.
~
w Track roller assembly mounting bolt : 3
156.9 - 215.8 Nm (16.0 - 22.0 kgm1
CLP02724
(PC27MRX. PC30MRX)

PC27 - 45MRX- 1 30-77

0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER

DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
I
1. Remove the snap ring and then the collars (1) and
(2).

2. Remove the shaft (3).

1

I CKP02992

3. Remove the flowing seal (4) from the collars (I)

and (2).

4. Remove two pieces of the floating seal (5) from

the roller (6).

CKP02993 CKP02994

5. Remove two pieces of the bushing (’7) from the

roller (6).

CKP02995

30-78 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER

ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Press fit two pieces of the bushing (7) in the roller
(6) using the tool L3.

2. Set two pieces of the floating seal (5) in the roller

(6) using the tool L4.
* Clean the O-ring and the O-ring contact sur-
face to degrease completely and dry them.
* Apply engine oil (E030-CD) to the floating seal
sliding surface and keep it free from dust.

CKP02996 CKP0299:

3. Set the floating seal (4) in the collars (I) and (2)
by using the tool L4.
* Clean the O-ring and the O-ring contact sur-
face to degrease completely and dry them.
* Apply engine oil (E030-CD) to the floating seal
sliding surface and keep it free from dust.

CKP02998

4. Set the O-ring and install the shaft (3) in the roller.

5. Set the collar (2) on the roller and fix it with a

snap ring.

6. Seal engine oil in the roller.

Roller inside :
Approx. 4Occ (E030-CD)
(PC27MRX. PC30MRX, PC35MRX)
Approx. 7Occ (E030-CD)
(PC4OMRX. PC45MRX)
CKP02992

7. Set the collar (1) on the roller and fix it with a

snap ring.

PC27 - 45MRX- 1 30-79

0
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER

REMOVAL OF CARRIER ROLLER

ASSEMBLY
PC27.30MR

1. Loosen valve (I) to relieve track shoe tension.

m

A The recoil spring cylinder is under extremely

high pressure. Never loosen the valve more
than one turn.
If the grease does not come out easily, move
the machine backwards and forwards.

_
- CWPO7329

2. Push up track (2) to a height where carrier roller

can be removed, then set block @ in position.

3. Remove carrier roller assembly (3). m

INSTALLATION OF CARRIER
ROLLER ASSEMBLY CWPO7330

l Carry out installation in the reverse order to re-

moval.

+ Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing track shoe tension.

& Carrier roller assembly mounting bolt :

Thread tightener (LT-2)
CLPO2725

30-80 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER

DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Remove cap (I).

2. Using snap ring pliers, remove snap ring (2).

% 2
3
3. Remove shaft (3). I

@
Q?ci

kid
CKPOZ999

4. Remove dust seal (4) from roller (5).

5. Remove 2 ball bearings (6) from roller (5).

I5 1

CKP03000 CKPO3101

ASSEMBLY OF CARRIER
6
1. Using tool L5, press fit 2 ball bearings (6) to roller
(5).

& Fill the ball portion of the bearing with

grease (Alvania EP or equivalent)

2. Using tool L6, press fit dust seal (4) to roller.

3. Fill the inside of the roller with grease. CKPO3102 CKP03103

Inside portion of roller :

Approx. 30 cc (Alvania EP or equivalent)

4. Install shaft (3) to roller. 3

5. Using snap ring pliers, install snap ring (2).

* Install the snap ring so that the edge on the
&
inside faces the tip of the shaft.

0@
21
6. Using tool L5, press fit cap (I).
It Cap press-fitting depth a : 10 mm

CKP03104

PC27 - 45MRX- 1 30-81

0
DISASSEMBLY AND ASSEMBLY RUBBER SHOE

REMOVAL OF RUBBER SHOE

ASSEMBLY PC27.30MR

Loosen lubricator (1) to relieve track shoe tension.

m

A The adjusting cylinder is under extremely

high pressure. Never loosen the lubricator
more than one turn.
If the grease does not come out easily, move
the machine backwards and forwards.

Swing upper structure 90”, then use work equip-

ment to raise track frame slightly.

Using pipes, remove rubber shoe assembly (3).

Fit the pipes inside the rubber shoe assembly,
PC36*40*46MR
rotate the rubber shoe assembly in reverse to raise
the rubber shoes from the idler, then slide to the LKl
outside to remove the rubber shoe assembly. I

km
r6?l Rubber shoe assembly :
120 kg (PC27MRX)
130 kg (PC30MRX. PC35MRX)
230 kg (PWOMRX, PC45MRX)

/
CWPO7.130

INSTALLATION OF RUBBER
SHOE ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

* Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing track shoe tension.
I \ I CWPO5400

30-82 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

REMOVAL OF HYDRAULIC
TANK ASSEMBLY
PC27MRX, PC30MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove fuel tank assembly.

For details, see RE-
MOVAL OF FUEL TANK ASSEMBLY.

2. Drain hydraulic oil.

- : Hydraulic tank : Approx. 28.5 fi

3. Disconnect fuel hose clamp (1) and (2).

4. Disconnect hydraulic filter inlet hose (3).

5. Remove reserve tank (4).

6. Disconnect hose (5) from swing motor.

CWPO6537
7. IDisconnect hose (6) from EPS valve. ,

8. Disconnect hose (7) from control valve.

9. Disconnect hose (8) from swivel joint.

10. IDisconnect pump suction hose (9).

11. qemove4 mounting bolts(lO), then liftoff hydrau-

lic tank assembly (11).

3 kg Hydraulic tank assembly : 35 kg

INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
PC27MRX, PC30MRX

. Carry out installation in the reverse order to re-

moval.

l Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
Then check the oil level again.
CWPO6539

Hydraulic tank : Approx. 28.5 !J (EOlO-CD)

PC27 - 45MRX-1 30-83

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

REMOVAL OF HYDRAULIC
TANK ASSEMBLY
PC35MR

a Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
AL Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove fuel tank assembly. For details, see RE-

MOVAL OF FUEL TANK ASSEMBLY.

2. Drain hydraulic oil.

- : Hydraulic tank : Approx. 28.5 l

3. Remove right lever stand assembly (I) with

bracket.

4. Disconnect 3 hoses (2) from hydraulic tank assem-

bly.
+ Fit a blind plug in the disconnected hose.
* After disconnecting the hoses, fit tags to dis-
tinguish them.

5. Remove reserve tank (3).

6. Disconnect3 hoses (4) from hydraulic tankassem-

bly.
* Fit a blind plug in the disconnected hose.
+ After disconnecting the hoses, fit tags to dis-
tinguish them.

Disconnect fuel hose clamp (5).

8. Ilisconnect pump suction hose (6) from hydrau-

lic tank assembly.

30-84 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

9. Lift off hydraulic tank assembly (7). m

& kg Hydraulic tank assembly : 60 kg

INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
PC35MRX

l Carry out installation in the reverse order to re-

moval.

6 Hydraulic tank assembly mounting bolt :

Thread tightener (LT-2)

l Refilling with oil (hydraulic tank)

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 tank : Approx. 28.5 e (EOIO-CD)

I&
m Filler plug (PC35MRX) :
181.3 - 240.1 Nm I18.5 - 24.5 kgm}

PC27 - 45MRX-1 30-85

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

REMOVAL OF HYDRAULIC
TANK ASSEMBLY
PC40MRX, PC45MRX

a Release the remaining pressure in the hydraulic

circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Drain hydraulic oil.

- : Hydraulic tank: Approx. 33 .t

2. Remove right cover and right under cover.

3. Remove hydraulic tank under cover (I)

4. Remove cover (2), which cover between hydrau-

lic tank and floor.

5. Remove 3 upper and lower covers (3) from hy-

draulic oil cooler.

6. Disconnect 3 hoses (4) at the middle of piping por-

tion from hydraulic tank assembly.
Sr Fit a blind plug in the disconnected hose.
* After disconnecting the hoses, fit tags to dis-
tinguish them.

30-86 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

7. Disconnect 2 hoses (5) from hydraulic tank assem-

bly.
* Fit a blind plug in the disconnected hose.
* After disconnecting the hoses, fit tags to dis-
tinguish them.

8. Remove breaker change valve bracket (6) mount-

ing bolts.
* Breaker specification machine only.

9. Disconnect pump suction hose (7) from hydrau-

lic tank assembly.

10. Lift off hydraulic tank assembly (8).

c+kg Hydraulic tank assembly : 55 kg

INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

l Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
Then check the oil level again.

Hydraulic tank : Approx. 33 L?(EOIO-CD)

PC27 - 45MRX-1 30-87

0
DISASSEMBLY AND ASSEMBLY FUELTANK

REMOVAL OF FUEL TANK

ASSEMBLY
PC27MRX, PCSOMRX, PC35MRX

g Disconnect the cable from the negative (-1 ter-

minal of the battery.

1. Open right upper cover (I), then remove right

cover (2) and right under cover (3).

2. Drain fuel.

- : Fuel tank : Approx. 42 fi (At full)

3. Remove bracket (4) for grease pump.

4. Remove vinyl cover (5).

5. Disconnect 2 battery cables (6), then remove bat-

tery (7).
* Disconnect fusible link from bracket.

6. Disconnect wiring connector (8) (M21).

7. Disconnect 2 hoses (9) from fuel tank assembly.

* After disconnecting the hoses, fit tags to dis-
tinguish them.

8. Disconnect drain cock mounting bracket (IO).

9. Disconnect 2 bands (11).

10. Remove fuel tank assembly(l2).

30-88 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY FUEL TANK

INSTALLATION OF FUEI TANK

ASSEMBLY
PC27MRX, PCSOMRX, PC35MRX

l Carry out installation in the reverse order to re-

moval.

m Band mounting nut:

5.9 + 0.49 Nm (0.6 i 0.05 kgml

l Refilling with fuel (fuel tank)

Fill fuel to fuel tank.

PC27 - 45MRX- 1 30-89

0
DISASSEMBLY AND ASSEMBLY FUEL TANK

REMOVAL OF FUEL TANK

ASSEMBLY
PC40MRX, PC45MRX

a Disconnect the cable from the negative (-) ter-

minal of the battery.

1. Drain fuel.

- : Fuel tank : Approx. 55 ~2(At full)

2. Remove floor frame assembly. For details, see RE-

MOVAL OF FLOOR FRAME ASSEMBLY.

3. Remove 2 fuel tank rear covers (I).

4. Disconnect 2 fuel hoses (2).

Ir After disconnecting the hoses, fit tags to dis-
tinguish them.

5. Remove air bleed hose (3) and fuel filler port (4).
m

6. Disconnect 2 band (5).

7. Remove fuel tank assembly (6).

INSTALLATION OF FUEI TANK

ASSEMBLY
PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

QKI Fuel filler port clamp :

8.8 f 0.5 Nm IO.9 + 0.05 kgcm)

m Band mounting nut :

5.9 * 0.49 Nm IO.6 f 0.05 kgm)

l Refilling with fuel (fuel tank)

Fill fuel to fuel tank.

30-90 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

REMOVAL OF MAIN PUMP

ASSEMBLY
PC27MRX, PC30MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.
A Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove counterweight assembly. For details, see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.

2. Drain hydraulic oil.

- : Hydraulic tank : Approx. 28.5 e

3. Disconnect suction hose (I).

4. Disconnect gear pump discharge hose (2).

5. Disconnect LS inlet hose (3).

6. Disconnect pump pressure inlet hose (4).

7. Disconnect main pump discharge hose (5).

8. Disconnect acceleration cable (6) from pump.

9. Remove mounting bolts, then remove main pump

assembly (7).

& kg Main pump assembly : 25 kg

j, Remove inner mounting bolt, using cuff
closed wrench.

INSTALLATION OF MAIN PUMP

ASSEMBLY
PC27MRX, PC30MRX

l Carry out installation in the reverse order to re-

moval.

l Refilling with oil (hydraulic tank)

Add oil through the oil fillerto the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

l Bleeding air
Bleed the air from main pump. For details, see
TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-91

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

DISASSEMBLY OF MAIN PUMP

ASSEMBLY
LPV30 (FOR PC30MRX-1)

1. Hydraulic pump assembly

Set hydraulic pump assembly (1) to tool 91.

DWP02184

2. Control pump assembly

1) Remove tube (2). then remove elbows (3) and
(4).
2) Remove control pump assembly (5).
3) Remove coupling (6).

s CVPO5591
/
CVPO5703

3. LS valve assembly
1) Remove LS valve assembly (7)

'CVPO5704

2) Disassemble LS valve assembly as follows.

* Measure screwed-in depth a of the plug
before disassembling.

CVPO5768

30-91-I PC27 - 45MRX-1

0
 MAIN PUMP
DISASSEMBLY AND ASSEMBLY

i) Remove piston (71) from sleeve (72).

ii) Remove spool assembly (73).
iii) Remove plug (74), then remove ball (75)
and spring (76) from spool (77).
iv) Loosen nut (78), then remove plug (79).
v) Remove O-ring (80) and backup ring (81)
from plug (79).
vi) Remove seat (82), spring (83), and seat
(84).
3) Remove seat (85).

79 - CVPO5592

/ / CVPO5593

4. Orifice plug
Remove orifice plug (18).

5. End cap assembly

1) Remove end cap assembly (19).

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Disassemble end cap assembly as follows.

i) Remove valve plate (20) from end cap (21).
* The valve plate may be stuck to the
cylinder block, so be careful when re-
moving.

CVPO5709

ii) Remove bearing outer race (40).

iii) Remove spacer (23).

CVPO5710 CVPO5711

6. Cylinder block, piston assembly

1) Using tool Q2, push down cylinder block.
* Set the tool so that the side with the
welded plate is facing the cylinder block.
Use gum tape or cloth to prevent the tool
and cylinder block from coming into di-
rect contact.
* The cylinder block sinks in only 4 - 5 mm,
so do not tighten the bolt more than nec-
essary.
2) Using puller 0, remove bearing inner race
(24).
* Rotate the bearing cage and check that the
teeth of the puller are not applied to the
cage while removing.
3) Remove retainer (25).

'PO5714

30-91-3 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

Remove cylinder block and piston assembly

(26).
* To ensure that the cylinder block and pis-
ton assembly come off together as one
unit, set the case facing slightly down
when removing.

/ / CVPO5715

Disassemble cylinder block and pistor 1 assem-

W as follows.
4 Remove piston assembly (27).
ii) Remove 7 pistons (28) from shoe r etainer
(2%.

CVPO5716 CVPO5717

iii) Remove retainer guide (30) from cylinder

block assembly (31).
iv) Remove 3 pins (32).

CVPO5716 CVPO5719

v) Set tool 93 to cylinder block assembly (31)

and compress spring.
vi) Remove snap ring (33), then remove tool
Q3.

w
DWP02166

PC27 - 45MRX-1 30-91-4

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

vii) Remove washer (34), spring (35), and

washer (36) from cylinder block (37).
34

35

CVPO5721

7. Rocker cam
1) Remove rocker cam (38) together with slider.

2) Remove slider (39) from rocker cam (38).

CVPO5723

8. Shaft assembly
Remove shaft assembly (40).

'PO5724

30-91-5 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

9. PC valve, servo piston assembly

* Before disassembling, measure adjustment
dimension b of the minimum swash plate
angle and adjustment dimension c of the
maximum swash plate angle.

CVPO5727

1) Loosen nut (43), then remove plug assem-

bly (44).

2) Disassemble plug assembly as follows.

* Before disassembling, measure 4
screwed-in adjustment dimension d of
the plug.
Remove nut (45), then remove plug (46)
from plug (47).

3) Remove seat (48), spring (49). and seat

(50).

PC27 - 45MRX-1 30-91-6

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

4) Loosen nut &I), then remove bolt (62).

* The nut and bolt form a set, so keep them
together as a set and be careful not to mix
them.

5) Remove
(53).

6) Disassemble PC valve and servo piston as-

sembly as follows.
i) Remove 3 seals (54) from piston (55).
ii) Remove plug (56).
iii) Remove plug (57) and piston (58).

10. Pump case

1) Remove plug (59).

30-91-7 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Remove snap ring (60), then remove spacer

(61).
3) Remove oil seal (62).

4) Remove bearing outer race (63).

I CVPO5737

PC27 - 45MRX-1 30-91-8

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

ASSEMBLY OF MAIN PUMP

ASSEMBLY
LPV30 (For PCSOMRX-1)
* Clean all parts, remove all burrs, check for dirt or
damage, and be particularly sure to clean the drill
hole oil passage.
* Coat the rotating and sliding surfaces of all parts
with engine oil (EOIO-CD) before assembling.
* Always check the contact of the following parts
before assembling. For details, see CHECKING
CONTACT BETWEEN PARTS. DWPO2187

1) Pump case and rocker cam

2) Cylinder block and valve plate
3) Valve plate and end cap

1. Pump case
1) Set pump case (64) to tool Ql.
2) Using tool Q4, press fit bearing outer race (63)
to case (64).

& Outside circumference of bearing:

Grease (G2-LI)

DWP02188
3) Fit O-ring and install plug (59).

D Plug:
14.7 - 19.6 Nm {I .5 - 2.0 kgm)

2. PC valve, servo piston assembly

1) Assemble PC valve and servo piston assem-
bly as follows.
i) Assemble piston (58) and plug (57) to pis-
ton (55).
* Assemble piston (58) so that the end
with more oil grooves is on the inside
of piston (55).
ii) Install plug (56).

6 Threaded portion:
Thread tightener
(Loctite #638 or equivalent)

w Plug:
27.4 - 34.3 Nm (2.8 - 3.5 kgm)
iii) Install 3 seals (54).
* To make sure that the seals fit the pis-
ton, wrap them with tape to hold in
position for 2 hours.

CVPO5733

30-91-g PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Assemble PC valve and servo piston assem-

bly (53).

53

: 2

3) Fit O-ring, install bolt (52), then secure with -7

, c,
nut (51).
* Set to adjustment dimension c for the
maximum swash plate angle measured
during disassembly.
. Standard adjustment dimension c:
17.6 mm

w Nut: 196 - 245 Nm (20 - 25 kgm)

\+
CVPO5740
II CVPO6741

4) Assemble seat (50), spring (49), and seat (48).

* Assemble the spring with the narrow coil
width facing the servo piston.
* Coat all parts thinly with grease to pre-
vent them from falling out, and bring them
into tight contact.

5) Assemble plug assembly as follows.

Assemble plug (46) to plug (47), then secure 47 - 46 45
with nut (45).
* Set to screwed-in dimension d for the plug
measured during disassembly.
. Standard screwed-in dimension d: 1.9
mm

m Nut:
24.5 - 34.3 Nm (2.5 - 3.5 kgm)

CVPO5729

PC27 - 45MRX-1 30-91-I 0

a
DISASSEMBLY AND ASSEMBLY MAIN PUMP

6) Fit O-ring to plug assembly (44), then secure

with nut (43).
* Set to adjustment dimension b for the
swash plate angle measured during dis-
assembly.
. Standard adjustment dimension b:
33.0 mm

m Nut: 98 - 118 Nm {IO - 12 kgm)

CVPO6743

3. Shaft assembly
1) Assemble shaft assembly as follows.
i) Using tool Q5, press fit bearing inner race
(45) to shaft (65).

& Inside circumference of bear-

ing: Grease (G2-LI)

ii) Install wear ring (41).

DWP02189

2) Install shaft assembly (40).

CVPO5594

4. Rocker cam
1) Install slider (39) to rocker cam (38).
* Install the slider so that the chamfered side
of the shaft hole faces the rocker cam.

CVPO5723

30-91-I 1 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Install rocker cam (38) and slider as one unit.

* Check that the sliding surface of the pump

1
case and rocker cam are fitted together 38
securely.

5. Cylinder block, piston assembly

1) Assemble cylinder block and piston assem-
bly as follows.
i) Set washer (36), spring (35), and washer
r
I
(34) to cylinder block (37).
37

ii) Set tool Q3 to cylinder block assembly (31)

and compress spring.
iii) Fit snap ring (48), then remove tool Q3.

a3q DWP02190

iv) Assemble 3 pins (32) to cylinder block as-

sembly (31).
* Coat the pins thinly with grease to pre-
vent them from falling out when they
are assembled to the pump case, and
bring into tight contact with the cylin-
der block.
v) Install retainer guide (50).

CVPO5747 CVPO5748

PC27 - 45MRX-1 30-91-I 2

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

vi) Assemble 7 pistons (28) to shoe retainer

(2%.
vii) Assemble piston assembly (27) to cylin-
der block assembly.

CVPO5717 CVPO5716

2) Install cylinder block and piston assembly (26).

* Check that the spline of the shaft and cyl-
inder block is meshed and that the sliding
portion of the rocker cam and piston shoe
are in tight contact.

CVPO5715

3) Install spacer (25).

* Install so that the stepped portion on the
inside diameter faces the cylinder block.

I / /
"CVPO5714

4) Using tool 96, press fit bearing inner race (24)

to shaft.

& Inside circumference of bearing:

Grease (G2-LI)

DWP02191

30-91-I 3 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

6. End cap assembly

1) Assemble end cap assembly as follows.
0 Assemble spacer (23) to end cap (21).
j, The spacer is a selected part, so tem-
porarily assemble a spacer of standard
thickness (1.6 mm). Carry out adjust-
ment of the thickness when measur-
ing the end play.
. Shim thickness: 1.6 - 2.2 mm (units of
1 .O mm)
ii) Using tool Q7, install bearing outer race
(22). DWP02192

& Outside circumference of bearing:

Grease (G2-LI)
iii) Install valve plate (20).
* Align the pin groove at the valve plate
end and the pin at the end cap end,
and check that the valve plate and end
cap are in tight contact.

CVPO5751

2) Fit O-ring and install end cap assembly (19).

& Mating surface of pump case:

Gasket sealant (LG-5 or LG-7)

m Mounting bolt:
98 - 123 Nm {IO - 12.5 kgm)
3) Measure end play of shaft as follows.
i) Set dial gauge @to tip of shaft.
ii) Apply a force of 980 - 1,078 N (100 - 110
kg} to shaft and measure end play.
. Permissible range for end play: 0.05 -
0.25 mm
* If the end play is more than the permis-
sible range, change the thickness of the
spacer inside the end cap to adjust the end

1
play.

CVPO5752

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY MAIN PUMP

3) Using tool QS, measure rotating torque of

shaft.
* Rotate the shaft at a constant speed (3 - 5
set/l turn) and measure the rotating
torque.
. Rotating torque: 6.86 - 20.6 Nm IO.7 - 2.1
kgm)
(Torque variation range: Max. 2.94 Nm IO.3
kgm)
* If the rotating - torque is not normal, disas-
semble again and look for the cause.
DWP02193

7. Oil seal
1) Using tool 99, press fit oil seal (62).

& Lip of oil seal: Grease (G2-LI)

DWP02194

2) Fit spacer (61) and install snap ring (60).

8. Orifice plug
Fit O-ring and install rear orifice plug (18).

w Orifice plug:
19.6 - 27.5 Nm (2 - 2.8 kgm)

30-91-I 5 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

9. LS valve assembly
1) Assemble seat (85).
2) Assemble LS valve assembly as follows.
0 Assemble seat (84), spring (83), and seat
(82) to sleeve (72).
ii) Assemble O-ring (80) and backup ring (81)
to plug (79).
* Install the O-ring and backup ring in
the position shown in the diagram on
the right.
iii) Install plug (79) to sleeve (72), the secure
with nut (78).
* Set to screwed-in dimension a for the
plug measured during disassembly.
l Standard screwed-in dimension a: 32
mm

m Nut: 49 - 69 Nm (5 - 7 kgm)
iv) Assemble spring (76), ball (75), and plug
(74) to spool (77).
v) Assemble spool assembly (73) to sleeve
(72).
vi) Assemble piston (71).

I CVPO5592

CVPO5768

3) Fit O-ring and install LS valve assembly (7).

w LS valve assembly:
49-59Nm{5-6kgm)

/ -/ 'CVPO5704

PC27 - 45MRX-1 30-91-I 6

a
DISASSEMBLY AND ASSEMBLY MAIN PUMP

10. Control pump assembly

1) Install coupling (6).
2) Fit O-ring to pump case, then install control
pump assembly (5).

m Mounting bolt:
27 - 34 Nm I2.8 - 3.5 kgm}
3) Fit elbows (4) and (3), then install tube (2).

m Elbow (4):
29.4 - 39.2 Nm (3.0 - 4.0 kgm}
Elbow (3): CVPO5703 1 1
58.8 - 78.4 Nm (6.0 - 8.0 kgm}
Tube:
19.6 - 29.4 Nm (2.0 - 3.0 kgm}

30-91-I 7 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

CHECKING CONTACT BETWEEN PARTS

* If either part ofthefollowing pairs of sliding parts
has been repaired or replaced with a repair part
(new part), check the contact as follows.
There is no need for this check if both parts of the
pair have been repaired or replaced with a repair
part (new part).
1) Pump case and rocker cam
2) Cylinder block and valve plate
3) Valve plate and end cap

1. Pump case and rocker cam

1) Remove all oil and grease from parts to be contact less
than 50% \
II
checked.
* Do not wipe with a cloth.
2) Paint pump case with inspection paint, then
put rocker cam on top. contact more
* Coat thinly with paint. than 90%

3) Push rocker cam with a force of 39.2 - 49.0 N

Contact
(4 - 5 kg) against pump case, and move it be- 50-90%
tween maximum swash plate angle on one
side and maximum swash plate angle on other
Contact less II
side. Repeat this process 2 or 3 times. than 50% DWPOZI 35
4) Remove rocker cam, transfer contact surface
to a tape, and check contact surface.
* The standard for the contact is as given
below.
(1) Within 30 mm of center (center por-
tion): Contact of more than 90%
(2) Range from center portion (30 mm) to
40 mm: Contact of 50% - 90%
(3) Not within width of 40 mm (outside):
Contact of less than 50%
l It is not permitted to have contact only
at the outside and no contact at the
center.
j, If the contact is defective and lapping is
carried out, it must always be carried out
for both parts together.

PC27 - 45MRX-1 30-91-I 8

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DISASSEMBLY AND ASSEMBLY MAIN PUMP

2. Cylinder block and valve plate

Valve Plate Centering tool
1, Make centering tool for cylinder block and
valve plate.
* The tool can be made from plastic, bakelite
or any other soft material.
2) Remove all oil and grease from parts to be
checked.
* Do not wipe with a cloth.
3) Paint cylinder block with inspection paint, then
put tool and valve plate on top.
* Coat thinly with paint.
block
4) Push valve plate with a force of 39.2 - 49.0 N DWPO2196
(4 - 5 kg) against cylinder block, turn valve
plate 90”, then turn it back to original posi-
tion. Repeat this process 2 or 3 times.
Seal portion:
5) Remove valve plate, transfer contact surface contact more than 80%
to a tape, and check contact surface.
-k The standard for the contact is as given
below.
(1) Seal portion (range within $70.7 mm):
Contact of more than 80% and no
break around whole circumference
(2) Land portion (range more than @77 Plate
/ \
mm): Contact of more than 60% and Cylinder block
Land port ion:
no break around whole circumference contact more than 60%
3. Valve plate and end cap DWPO2197
1) Remove all oil and grease from parts to be
checked.
* Do not wipe with a cloth.
2) Paint end cap with inspection paint, then put
valve plate on top.
* Coat thinly with paint.
3) Push valve plate with a force of 39.2 - 49.0 N
(4 - 5 kg) against end cap, turn valve plate 90”,
then turn it back to original position. Repeat
this process 2 or 3 times.
4) Remove valve plate, transfer contact surface
to a tape, and check contact surface.
* The contact of the mating surface of the
valve plate and end cap must cover at least
80% without any variation.
* If the contact is defective, use a surface
plate and correct by lapping.

At this surface there

must be no Play and
contact must be more
than 80%
DWPO2198

30-91-I 9 PC27 - 45MRX-1

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DISASSEMBLY AND ASSEMBLY MAIN PUMP

DISASSEMBLY OF MAIN PUMP

ASSEMBLY
LPD25+25 (FOR PC40MRX-1)
1. Hydraulic pump assembly
Set hydraulic pump assembly (1) to tool Sl.

2. Gear pump
1) Remove tube (Z), then remove elbows (3) and
(4).
2) Remove gear pump (5).
3) Remove coupling (6).

3. LS valve assembly
1) Remove LS valve assembly (7).

2) Disassemble LS valve assembly as follows.

* Measure screwed-in depth a of the plug
before disassembling.

CVPO5768

PC27 - 45MRX-1 30-91-20

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DISASSEMBLY AND ASSEMBLY MAIN PUMP

0 Remove piston (8) from sleeve (9).

ii) Remove spool assembly (10).
iii) Remove plug (1 I), then remove ball (12)
and spring (13) from spool (14). a
iv) Loosen nut (15), then remove plug (16).
v) Remove O-ring (17) and backup ring (18)
from plug (16).
vi) Remove seat (19). spring (20), and seat
(21).

3) Remove seat (22) from LS valve mounting

hole.

4. Orifice plug
1) Remove orifice plug (23)

2) Remove O-ring (24) and 2 backup rings (25)

from orifice plug (23).

30-91-21 PC27 - 45MRX-1

a
DISASSEMBLY AND ASSEMBLY MAIN PUMP

5. Travel deviation adjustment plug

1) Remove 2 nuts (26), then remove 2 plugs (27).

2) Remove O-ring (28) and backup ring (29) from

plug (27).

6. Average pressure reducing valve

1) Remove nut (30), then remove plug (31).
2) Remove spring (32).

3) Remove spool (33).

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY MAIN PUMP

7. End cap assembly

1) Remove end cap assembly (34).

2) Disassemble end cap assembly as follows.

i) Remove valve plate (35) from end cap (36).
* The valve plate may be stuck to the
cylinder block, so be careful when re-
moving

ii) Remove needle bearing (37).

8. Cylinder block, piston assembly

1) Remove cylinder block and piston assembly
(36).
* To ensure that the cylinder block and pis- :L$
ton assembly come off together as one “4
unit, set the case facing slightly down
when removing.

30-91-23 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Disassemble cylinder block and piston assem-

b’y as follows:
0 Remove piston assembly (39) from cylin-
der block assembly (40).
ii) Remove 10 pistons (41) from shoe retainer
(42).

iii) Remove retainer guide (43) from cylinder

block assembly (40).
iv) Remove 3 pins (44).

v) Set tool S2 to cylinder block assembly (40)

and compress spring.
vi) Remove snap ring (45), then remove tool
s2.

CVZO0723

vii) Remove washer (77), spring (46), and

washer (47) from cylinder block (48).

CVZO0724

PC27 - 45MRX-1 30-91-24

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DISASSEMBLY AND ASSEMBLY MAIN PUMP

9. Rocker cam
1) Remove rocker cam (49) together with slider.

2) Remove slider (50) from rocker cam (49).

10. PC valve, servo piston assembly

* Before disassembling, measure adjustment
dimension b of the minimum swash plate
angle and adjustment dimension c of the
maximum swash plate angle.

1) Remove nut @I), then remove plug as-

sembly (52).

30-91-25 PC27 - 45MRX-1

a
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Disassemble plug assembly as follows.

* Measure screwed-in dimension d of 5
the plug before disassembling.
Remove nut (53), then remove plug (54)
from plug (55).

3) Remove 2 seats (56) and spring (57).

* There is also a seat installed inside the
spring, so remove it.

4) Remove nut (58), then remove bolt (59).

5) Remove PC valve and servo piston assem-

bly (60).

PC27 - 45MRX-1 30-91-26

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

6) Disassemble PC valve and servo piston as-

sembly as follows.
i) Remove 3 seals (61) from piston (62).
ii) Remove plug (63).
iii) Remove plug (64) and piston (65).

11. Bleeder
Remove bleeder (66), then remove plug (67).

12. Oil seal

1) Remove snap ring (68), then remove cover
(69).

2) Remove oil seal (70) from cover (69).

30-91-27 PC27 - 45MRX-1

a
DISASSEMBLY AND ASSEMBLY MAIN PUMP

13. Case, shaft assembly

Remove case and shaft assembly (71) from tool
Sl.

PC27 - 45MRX-1 30-91-28

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DISASSEMBLY AND ASSEMBLY MAIN PUMP

ASSEMBLY OF MAIN PUMP

ASSEMBLY
LPD25+25 (FOR PC40MRX-1)
* Clean all parts, remove all burrs, check for dirt or
damage, and be particularly sure to clean the drill
hole oil passage.
* Coat the rotating and sliding surfaces of all parts
with engine oil (EOIO-CD) before assembling.
* Always check the contact of the following parts
before assembling. For details, see CHECKING
CONTACT BETWEEN PARTS.
1) Pump case and rocker cam
2) Cylinder block and valve plate
3) Valve plate and end cap

1. Case, shaft assembly

1) Using tool S3, press fit ball bearing (76) to
shaft (75).

& Press-fitting surface of bearing:

Grease (G2-LI)
* Press fit the bearing UP to the end face of
the stepped portion of the shaft.
2) Install snap ring (74).
* Install the snap ring so that the inside di-
ameter portion that is not tapered faces
the bearing.
3) Using tool S4 and press, press fit shaft assem-
bly (72) to case (73).

& Press-fitting surface of bearing:

Grease (G2-LI)

CVZO0742

4) Set case and shaft assembly (71) to tool Sl.

30-91-29 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2. Bleeder
1) Fit O-ring and install plug (67) to case.

m Plug:
19.6 - 24.5 Nm (2.0 - 2.5 kgm)
2) Install bleeder (76).

w Bleeder:
7.8 - 9.8 Nm (0.8 - 1 .O kgm)

3. PC valve, servo piston assembly

1) Assemble PC valve and servo piston as fol-
lows.
i) Assemble piston (65) and plug (64) to pis-
ton (62).
* Assemble piston (65) so that the end
with more oil grooves is on the inside
of piston (62).
ii) Install plug (63).

& Thread portion:

Thread tightener
(Loctite #638 or equivalent)

w Plug:
58.8 - 73.5 Nm (6.0 - 7.5 kgm)
iii) Install 3 seals (61).
* To make sure that the seals fit the pis-
ton, wrap them with tape to hold in
position for 2 hours.
2) Assemble PC valve and servo piston assem-
bly (60).

3) Fit O-ring and install bolt (59), then secure with

nut (58).

w Nut: 196 - 245 Nm (20 - 25 kgm)

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY MAIN PUMP

* Set to adjustment dimension c for the

maximum swash plate angle measured
during disassembly.
. Standard adjustment dimension c:
18.9 mm

4) Assemble 2 seats (56) and spring (57).

* Assemble a seat inside the spring also.
* Assemble the spring with the narrow coil
width facing the servo piston.
* Coat all parts thinly with grease to pre-
vent them from falling out, and bring them
into tight contact.

5) Assemble plug assembly as follows.

Fit O-ring and install plug (54) to plug (55),
then secure with nut (53).
* Set to screwed-in dimension d for the plug
measured during disassembly.
. Standard screwed-in dimension d: 2.3
mm

@L Nut: 24.5 - 34.3 Nm (2.5 - 3.5 kgm)

6) Fit O-ring and install plug assembly (52), then

secure with nut (51).

w Nut: 98.1 - 117.7 Nm {IO - 12 kgm)

30-91-31 PC27 - 45MRX-1

a
DISASSEMBLY AND ASSEMBLY MAIN PUMP

* Set to adjustment dimension b for the

_, b ,_
minimum swash plate angle measured
during disassembly.
. Standard adjustment dimension b:
33.8 mm

4. Rocker cam
1) Install slider (50) to rocker cam (49).
* Install the slider so that the chamfered side
of the shaft hole faces the rocker cam.

2) Install rocker cam (49) and slider as one unit.

* Check that the sliding surface of the pump
case and rocker cam are fitted together
securely.

5. Cylinder block, piston assembly

1) Assemble cylinder block and piston assem-
bly as follows.
i) Set washer (47), spring (46), and washer
(77) to cylinder block (48).

CVZO0724

PC27 - 45MRX-1 30-91-32

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

ii) Set tool S2 to cylinder block assembly (40)

and compress spring.
iii) Fit snap ring (45), then remove tool S2.

iv) Assemble 3 pins (44) to cylinder block as-

sembly (40).
* Coat the pins thinly with grease to pre-
vent them from falling out when they
are assembled to the pump case, and
bring into tight contact with the cylin-
der block.
v) Install retainer guide (43).

vi) Assemble 10 pistons (41) to shoe retainer

(42).
vii) Assemble piston assembly (39) to cylin-
der block assembly (40).

2) Install cylinder block and piston assembly (38).

* Check that the spline of the shaft and cyl-
inder block is meshed and that the sliding
portion of the rocker cam and piston shoe
are in tight contact.

30-91-33 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

6. End cap assembly

1) Assemble end cap assembly as follows.
i) Using tool S5, press fit needle bearing (37)
to end cap (36).

& Press-fitting surface of bearing:

Grease (G2-LI)
* Press fit the bearing up to the end face
of the mounting hole.

ii) Install valve plate (35).

* Align the pin groove of the valve plate
end and the pin of the end cap end,
and check that the valve plate and end
cap are in tight contact.

2) Fit O-ring and install end cap assembly (34).

& Mating surface of pump case:

Gasket sealant (LG-5 or LG-7)

m Mounting bolt:
98 - 123 Nm {IO - 12.5 kgm)

3) Using tool S6, measure rotating torque of

shaft.
* Rotate the shaft at a constant speed (3 - 5
set/l turn) and measure the rotating
torque.
. Rotating torque: 6.86 - 20.2 Nm CO.7 - 2.1
kgm)
(Torque variation range: Max. 2.94 Nm (0.3
kgm)
* If the rotating torque is not normal, disas-
semble again and look for the cause.

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY MAIN PUMP

7. Oil seal
1) Using tool S7, press fit oil seal (70) to cover
(69).

& Lip of oil seal: Grease (G2-LI)

,70

cvz

2) Fit O-ring and install cover (69), then install

snap ring (68).

~~~~~~~~~~~~
8. Average pressure reducing valve
1) Assemble spool (33).
* Check that the spool moves smoothly.

2) Assemble spring (32).

3) Fit O-ring and install plug (31), then secure
Jvith nut (30).
* Tighten the plug so that it is the same
height as the nut.
lScrewed-in height: 10.7 mm

m Nut: 24.5 - 34.3 Nm (2.5 - 3.5 kgm}

30-91-35 PC27 - 45MRX-1

a
DISASSEMBLY AND ASSEMBLY MAIN PUMP

9. Travel deviation adjustment plug

1) Install backup ring (29) and O-ring (28) to plug
(27).

2) Install 2 plugs (27).

m Plug: 2.9 - 4.7 Nm (0.3 - 0.5 kgm)

3) Install 2 nuts (26).

m Nut: 11.8 - 14.7 Nm (1.2 - 1.5 kgm}

10. Orifice plug

1) Install 2 backup rings (25) and O-ring (24) to
plug (23).
* Install the O-ring and backup rings in the
position shown in the diagram on the
right.

CVZOO712

2) Fit O-ring and install orifice plug (23).

w Orifice plug:
19.6 - 27.5 Nm (2.0 - 2.8 kgm)

PC27 - 45MRX-1 30-91-36

DISASSEMBLY AND ASSEMBLY MAIN PUMP

11. LS valve assembly

1) Assemble seat (22) to LS valve mounting hole.

2) Assemble LS valve assembly as follows.

i) Assemble seat (21), spring (20), and seat
(19) to sleeve (9).
ii) Assemble O-ring (17) and backup ring (18)
to plug (16).
* Install the O-ring and backup ring in
the position shown in the diagram on
the right.
iii) Install plug (16) to sleeve (9), then secure
with nut (15).
* Align with screwed-in dimension a of
the plug measured before disassem-
bly.
- Standard screwed-in dimension a: 32
mm

iv) Assemble spring (13), ball (12), and plug

(11) to spool (14).

&Threaded portion of plug:

Thread tightener
(Loctite #638 or equivalent)

w Plug:
2.94 - 5.88 Nm (0.3 - 0.6 kgm)
v) Assemble spool (10) to sleeve (9). CVPO5768
vi) Assemble piston (8).
3) Fit O-ring and install LS valve assembly (7).

m LS valve assembly:
49 - 59 Nm (5 - 6 kgm}

30-91-37 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

12. Gear pump

1) Install coupling (6).
2) Install gear pump (5).
3) Fit elbows (4) and (3), and install tube (2).

m Elbow (4):
58.8 - 78.4 Nm (6 - 8 kgm)

m Elbow (3):
29.4 - 39.2 Nm {3 - 4 kgm)

m Tube:
19.6 - 29.4 Nm {2 - 3 kgm)

PC27 - 45MRX-1 30-91-38

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

CHECKING CONTACT BETWEEN PARTS

j, If either part ofthe following pairs of sliding parts
has been repaired or replaced with a repair part
(new part), check the contact as follows.
There is no need for this check if both parts of the
pair have been repaired or replaced with a repair
part (new part).
1) Pump case and rocker cam
2) Cylinder block and valve plate
3) Valve plate and end cap

1. Pump case and rocker cam

1) Remove all oil and grease from parts to be
Contact less
checked. than 50%
* Do not wipe with a cloth.
Contact
2) Paint pump case with inspection paint, then 50-90%
put rocker cam on top.
* Coat thinly with paint. Contact more
* Install in the direction shown in the dia- than 90%

gram on the right.

Contact
3) Push rocker cam with a force of 39.2 - 49.0 N 50-90%
(4 - 5 kg) against pump case, and move it be-
tween maximum swash plate angle on one
Contact less
side and maximum swash plate angle on other than 50%
side. Repeat this process 2 or 3 times.
4) Remove rocker cam, transfer contact surface
to a tape, and check contact surface.
* The standard for the contact is as given
below.
(1) Within 30 mm of center (center por-
tion): Contact of more than 90%
(2) Range from center portion (30 mm) to
40 mm: Contact of 50% - 90%
(3) Not within width of 40 mm (outside):
Contact of less than 50%
. It is not permitted to have contact only
at the outside and no contact at the
center.
* If the contact is defective and lapping is
carried out, it must always be carried out
for both parts together.

30-91-39 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2. Cylinder block and valve plate

Valve Plate Centering tool
1, Make centering tool for cylinder block and
valve plate.
* The tool can be made from plastic, bakelite
or any other soft material.
2) Remove all oil and grease from parts to be
checked.
* Do not wipe with a cloth.
3) Paint cylinder block with inspection paint, then
put tool and valve plate on top.
* Coat thinly with paint.
- CYI inder block
4) Push valve plate with a force of 39.2 - 49.0 N DWPO2200
(4 - 5 kg) against cylinder block, turn valve
plate 90”, then turn it back to original posi-
tion. Repeat this process 2 or 3 times.
Seal port ion:
5) Remove valve plate, transfer contact surface contact more than 80%
to a tape, and check contact surface. \
-k The standard for the contact is as given
below.
(1) Seal portion (range of 490.5 mm from
bottom): Contact of more than 80%
and no break around whole circum-
ference
(2) Land portion (range of $90.5 mm - CYI inde; block \
Land portion:
$112 mm): Contact of more than 60% contact rn~re than 60%

and no break around whole circum- DWP0220 I

ference
3. Valve plate and end cap
Remove all oil and grease from parts to be
checked.
* Do not wipe with a cloth.
Paint end cap with inspection paint, then put
valve plate on top.
* Coat thinly with paint.
Push valve plate with a force of 39.2 - 49.0 N
(4 - 5 kg) against end cap, turn valve plate 90”,
then turn it back to original position. Repeat
this process 2 or 3 times.
Remove valve plate, transfer contact surface
to a tape, and check contact surface.
* The contact of the mating surface of the
valve plate and end cap must cover at least
80% without any variation.
* If the contact is defective, use a surface
plate and correct by lapping.

At this surface there

must be no Play and
contact must be more
than 60%
DWPO2198

PC27 - 45MRX-1 30-91-40

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DISASSEMBLY AND ASSEMBLY MAIN PUMP

REMOVAL OF MAIN PUMP

ASSEMBLY
PC35MRX, PC40MR, PC45MRX

a Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
a Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.
a Disconnect the cable from the negative (-) ter-
minal of the battery.
1. Drain hydraulic oil.

- : Hydraulic tank : Approx. 33 .Q

2. qemove counterweight assembly. For details, see

3EMOVAL OF COUNTERWEIGHT ASSEMBLY.
3. qemove muffler (I) and exhaust pipe (2).
4. Disconnect hoses from main pump shown under.
l Suction tube : (3)
l Pump pressure inlet hose : (4)
l Main pump discharge (PI) hose : (5)
l Main pump discharge (P2) hose : (6)
l Gear pump discharge (P3) hose : (7)
l LS inlet hose : (8)
5. I_ift off main pump assembly (9). m
f Remove inner mounting bolt, using cuff
closed wrench.

3 kg Main pump assembly : 25 kg

INSTALLATION OF MAIN PUMP

ASSEMBLY
PC35MRX, PC40MRX, PC45MRX
l Carry out installation in the reverse order to re-
moval.

& shaft sprain :

Molybdenum disulphide grease (LM-P)

m Main pump mounting bolt :

98 - 123 Nm {IO - 12.5 kgm}

l Refilling with oil (hydraulic tank)

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.

m Filler plug :
181.3 -240.1 Nm I18.5 -24.5 kgm}

l Bleeding air
Bleed the air from main pump. For details, see
TESTING AND ADJUSTING, Bleeding air.

30-92 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY SWING GEAR PUMP

REMOVAL OF SWING GEAR

PUMP ASSEMBLY
A Stop the machine on the horizontal ground, then
lower the work equipment completely to the
ground and stop the engine.
a Release the remaining pressure in the hydrau-
lic circuit and hydraulic tank. For details, see
TESTING AND ADJUSTING, Releasing remain-
ing pressure in hydraulic circuit and hydraulic
tank.
a Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove counterweight assembly. For details, see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.

2. Disconnect gear pump discharge hose (I).

3. Disconnect joint tube (2).

4. Remove mounting bolt (3), then remove gear

pump assembly (4). m

INSTALLATION OF SWING
GEAR PUMP ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

w Gear pump mounting bolt:

27 - 34 Nm 12.8 - 3.5 kgm1
(PC27MRX, PC30MRXI
98.1 - 122.6 Nm {IO - 12.5 kgml
(PC35MRX, PC40MRX. PC45MRX)

l Refilling with oil (hydraulic tank)

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.

w Filler plug (PC35MRX) :

181.3 - 240.1 Nm 118.5 - 24.5 kgml

l Bleeding air
Bleed the air from main pump. For details, see
TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX-1 30-93

0
DISASSEMBLY AND ASSEMBLY PPC PUMP

REMOVAL OF PPC PUMP

ASSEMBLY
PC35MRX

g Release the remaining pressure in the hydraulic

circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove seat bracket. For details, see REMOVAL

OF SEAT BRACKET.

2. Remove starting motor front cover.

3. Disconnect wiring connector (I) (T4), then discon-

nect 2 wires (2).

4. Disconnect 2 hoses (3) from PPC pump assem-

bly.

5. Remove PPC pump assembly (4).

INSTALLATION OF PPC PUMP

ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

30-94 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY PPC PUMP

REMOVAL OF PPC PUMP

ASSEMBLY
PC40MRX, PC45MRX

a Release the remaining pressure in the hydraulic

circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove operator cabin assembly. For details, see

REMOVAL OF OPERATOR CABIN ASSEMBLY.
* Operator cabin specification machine only.

2. Remove floor frame right cover (1).

3. Lift off cover (2) from upper side of engine stay.

* Canopy specification cabin machine only.

r&lkg cover : 25 kg

4. Lift off frame assembly (3).

& kg Frame assembly : 40 kg

5. Remove 2 hoses (4) from PPC pump assembly.

6. Remove PPC pump assembly (5).

INSTALLATION OF PPC PUMP

ASSEMBLY
PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
PC27MRX, PC30MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.
a Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Drain hydraulic oil.

- : Hydraulic tank : Approx. 28.5 !I

2. Remove handrail (1).

3. Remove floor mat, then remove travel speed se-
lector switch (2) from floor.
* Disconnect wiring connector (S3) for travel
speed selector switch.
4. Remove floor plate (3).
5. Disconnect each 2 piping on control valve follow-
ing (4) (to swing motor), (5) (from main pump),
(6) (to right travel motor), (7) (to left travel mo-
tor), (8) (to boom cylinder), (9) (to arm cylinder).
6. Disconnect each 2 piping on control valve follow-
ing (IO) (to bucket cylinder), (I I) (to boom cylin-
der), (12) (to blade cylinder).
* After disconnecting the hoses, fit tags to dis-
tinguish them.
7. Disconnect hose (13) from gear pump.
8. Disconnect hose (14) to left side of swing motor.
9. Disconnect control valve as following, (15) (to hy-
draulic tankland (16) (to swing motor bearing),
then disconnect hose (9) to blade cylinder.
10. Disconnect PPC hoses as following, (17) (swing
right), (18) (bucket dump), (19) (arm out), (20)
(boom lower).
11. Disconnect hose (21) from pump LS valve.
12. Disconnect blade control lever (22).
13. Disconnect link (23) for boom swing.
14. Disconnect hose (24) to swing motor right side.
15. Disconnect PPC hoses as following, (25) (swing
LEFT), (26) (bucket CURL), (27) (arm IN), (28)
(boom RISE).
16. Disconnect link between left travel (29) and right
travel (30).
17. Disconnect hose (31) to solenoid valve.
18. Disconnect hose (32) to main pump (PI L port).
19. Disconnect hose (33) to oil cooler.

CWP06552

30-96 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

20. Disconnect hose (34) to hydraulic tank.

21. Remove mounting bolt (35), then lift off main con-
trol valve assembly (36).

&I kg Main control valve assembly : 35 kg

INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
PC27MRX, PCSOMRX

Carry out installation in the reverse order to re-

moval.

Check the blade control lever, travel control le-

ver, and swing control pedal. For details, see TEST-
ING AND ADJUSTING, Adjusting control lever
and pedal.

Refilling with oil (hydraulic tank)

Add oil through the oil fillerto the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

Bleeding air
Bleed the air from the hydraulic circuit. For de-
tails, see TESTING AND ADJUSTING, Bleeding
air.

PC27 - 45MRX- 1 30-97

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
PC35MRX

A Release the remaining pressure in the hydraulic

circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Remove 2 floor plates (I).

2. Disconnect drain hose (2) from PPC valve assem-

bly for breaker.
* Breaker specification only.

3. Disconnect all hoses (3) from upper of main con-

trol valve assembly. m
* It may be necessary to remove some of
nipples in order to remove all the main hoses.

* After disconnecting the hoses, fit tags to dis-

tinguish them.

4. Disconnect all right and left pilot hoses (4) from

main control valve assembly.

5. Disconnect control linkage shown under. m

l Swing control linkage : (5)
l Blade control linkage : (6)
l Right travel control linkage : (7)
l Left travel control linkage : (8)
* Make sure the mounting dimension before
disconnecting.

6. Lift off main control valve assembly (9).

&I kg Main control valve assembly : 35 kg

30-98 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
PC35MRX

l Carry out installation in the reverse order to re-

moval.

m O-ring boss type nipple :

Thread size lightning torque

14 x 1.5 1 34.3 rt 4.9 Nm 1 {3.5 + 0.5kgm)

18 x 1.5 93.1_‘,::; Nm (9.51 :.5 kgm}

24 x 1.5 142.1_*:~:~Nm {14.5_*& kgm}

Check the blade control lever, travel control

lever, and swing control pedal. For details, see
TESTING AND ADJUSTING, Adjusting control
lever and pedal.

l Refilling with oil (hydraulic tank)

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.

QZI Filler plug :

181.3 - 240.1 Nm t18.5 - 24.5 kgm}

l Bleeding air
Bleed the air from the hydraulic circuit. For de-
tails, see TESTING AND ADJUSTING, Bleeding
air.

PC27 - 45MRX-1 30-99

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
PC40MRX, PC45MRX

A Release the remaining pressure in the hydraulic

circuit and hydraulic tank. For details, see TEST-
ING AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit and hydraulic tank.

1. Open right upper cover (I), then remove right

cover (2) and right under cover (3).

2. Disconnect all hoses (4) from upper of main con-

trol valve assembly. m
* It may be necessary to remove some of
nipples in order to remove all the main hoses.
Ir After disconnecting the hoses, fit tags to dis-
tinguish them.

3. Disconnect all right and left pilot hoses (5) from

main control valve assembly.

4. Disconnect 2 control linkages (6) and 2 control

cables (7) from main control valve assembly.
112
t Make sure the mounting dimension before
disconnecting.

5. Lift off main control valve assembly (8).

b kg Main control valve assembly : 50 kg

30- 100 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
PC4OMRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

m O-ring boss type nipple :

Thread size lightning torque

14x 1.5 34.3 + 4.9 Nm 13.5 * 0.5kgm)

18 x 1.5 93.1: ,I; Nm 1 I9.51 :.5 kgml

24x 1.5 1 142.1::::: Nm 1 I14.5+& kgm)

* Check the blade control lever, travel control

lever, and swing control pedal. For details, see
TESTING AND ADJUSTING, Adjusting control
lever and pedal.

l Refilling with oil (hydraulic tank)

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.

l Bleeding air
Bleed the air from the hydraulic circuit. For de-
tails, see TESTING AND ADJUSTING, Bleeding
air.

PC27 - 45MRX- 1 30-l 01

a
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

+ Do not remove the long connecting bolt at the 6) Remove bolt (20).
bottom of the control valve. * Loosen the bolt with the spool still as-
Remove the short connecting bolt at the top sembled inside the valve.
of the control valve when adding a service
valve. 7) Remove retainer (21). spring (22), and re-
Ir The spools and pressure compensation valves tainer (23).
(both the flow control valves and reducing
valves) are not interchangeable between 8) Remove spool (24).
blocks, so be sure to mark them when disas-
sembling. 9) Remove 2 seals (25).
* Do not remove the plug at the end of the
spool. 10) Remove plug (26).
* The pressure of the central safety valve can-
not be set when it is mounted on the machine, 11) Remove block (27).
so do not disassemble it.
12) Remove suction valve assembly (28).
1. Top cover
1) Remove plug (1). 13) Remove plug (29), then remove spring
* In some cases there is pressure re- (30) and plug (31).
maining in the central safety valve cir-
cuit, so loosen the plug slowly. 4. Boom swing control valve
Ir Remove the O-ring and backup ring. I) Remove plate (32).

2) Remove 2 plugs (2). 2) Remove cases (33) and plate (34).

2. Swing control valve 3) Remove bolt (35).

1) Remove cases (3) and (4). Ir Loosen the bolt with the spool still as-
sembled inside the valve.
2) Remove bolt (5).
Ir Loosen the bolt with the spool still as- 4) Remove retainer (36), spring (37), and re-
sembled inside the valve. tainer (38).

3) Remove retainer (6), spring (7), and re- 5) Remove spool (39).
tainer (8).
6) Remove 2 seals (40).
4) Remove spool (9).
7) Remove plug (41). then remove spring
5) Remove block (10). (42), piston (43), valve (44), and spacer
(45).
3. Blade and breaker control valve
I) Remove case (11) and plate (12). 8) Remove plug (46), then remove valve (47).

2) Remove case (13) and plate (14). 9) Remove 2 suction valve assemblies (48).

3) Remove bolt (15). 10) Remove plug (49), then remove spring
* Loosen the bolt with the spool still as- (50) and valve (51).
sembled inside the valve.
5. Bucket control valve
4) Remove retainer (16), spring (17), and re- 1) Remove cases (52) and (53).
tainer (18).
2) Remove bolt (54).
5) Remove spool (19). + Loosen the bolt with the spool still as-
sembled inside the valve.

PC27 - 45MRX-1 30- 103

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

3) Remove retainer (551, spring (561, and re-

tainer (57).

4) Remove spool (58).

5) Remove plug (59), then remove spring

(60), piston (611, valve (621, and spring
(63).

6) Remove plug (64), then remove valve (65).

7) Remove suction valve assembly (66).

8) Remove plug (67). then remove spring

(68) and valve (69).
* remove 2 sets

6. Arm control valve

1) Remove cases (70) and (71).

2) Remove bolt (72).

* Loosen the bolt with the spool still as-
sembled inside the valve.

3) Remove retainer (73). spring (74), and re-

tainer (75).

4) Remove spool (76).

5) Remove plug (77), then remove spring

(78), piston (79), valve (80), and spring
(81).

6) Remove plug (82). then remove valve (83).

7) Remove suction valve assembly (84).

8) Remove plug (85). then remove spring

(86) and valve (87).

30-l 04 PC27 - 45MRX- 1

a
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

MAIN CONTROL VALVE BOTTOM (Z/Z)

is

CWPO6610

PC27 - 45MRX-1 30-105

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

7. Boom control valve 9. Main relief valve

1) Remove cases (I) and plate (2). Remove main relief valve assembly (37).
t For details of further disassembly, see Dis-
2) Remove bolt (3). assembly of main relief valve assembly.
t Loosen the bolt with the spool still as-
sembled inside the valve. 10. Central safety valve
Remove central safety valve assembly (38).
3) Remove retainer (4). spring (5), and re- +r Remove the O-ring and backup ring.
tainer (6).
11. Unload valve
4) Remove spool (7). Remove plug (39). then remove spring (40)
and valve (41).
5) Remove plug (8), then remove spring (9), * Remove O-ring and backup ring.
piston (IO), valve (1 I) and spring (12).
12. Self pressure reducing valve
6) Removeplug(l3),then removevatve(14). 1) Remove plug (42), then remove spring
(43) and valve (44).
7) Remove 2 suction valve assemblies (15).
2) Remove pilot relief valve assembly (45).
8) Remove boom lock valve assembly (16). * For details of further disassembly, see
Disassembly of main relief valve as-
9) Remove plug (17). sembly.
* Remove the O-ring and backup ring.
3) Remove spring (46) and spool (47).
10) Remove seat (18), valve (19). spring (20)
and retainer (21). 4) Remove block (48), then remove filter (49).

8. R.H. travel control valve & L.H. travel control 13. Cooler check valve
valve 1) Remove plug (50), then remove spring
* Disassemble the R.H. and L.H. travel con- (51) and valve (52).
trol valves in the same way.
2) Remove plug (23).
1) Remove plate (22).
14. Top cover
2) Remove cases (23) and plate (24). * When adding a service valve, remove
cover (54).
3) Remove bolt (25).
+ Loosen the bolt with the spool still as-
sembled inside the valve.

4) Remove retainer (26), spring (27). and re-

tainer (28).

5) Remove spool (29).

6) Remove 2 seals (30).

7) Remove plug (31). then remove spring

(32). piston (33)and valve (34).

8) Remove plug (35), then remove valve (36).

30- 106 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

DISASSEMBLY OF MAIN RELIEF VALVE

ASSEMBLY
* When the adjustment screw is loosened, the set
pressure will change, so before disassembling,
measure the dimension of the protrusion from the
adjustment screw nut.

1. Remove O-ring (I 1 and backup ring (2).

2. Remove nut (3).

3. Remove screw (41, then remove spring (5) and

poppet (6).

4. Remove ring (71, then remove valve (8) and spring

(9).

CKP03132

DlSASSEMBLY OF PILOT RELEIFE VALVE

ASSEMBLY
When the adjustment screw is loosened, the set
pressure will change, so before disassembling,
measure the dimension of the protrusion from the
adjustment screw nut.

Remove O-ring (I) and backup ring (2).

Remove nut (3).

Remove screw (4L then remove spring (5), washer

(6) and poppet (7).

CKP03133

PC27 - 45MRX- 1 30-107

a
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY

PC27MRX, PCSOMRX
MAIN CONTROL VALVE BOTTOM (2/2)

34
33 32
31
4)
0
i d0

CWPO6610

30-108 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

The spools and pressure compensation valves 6. Main relief valve

(both the flow control valves and reducing Fit O-ring and install main relief valve assem-
valves) are not interchangeable between bly (37).
blocks, so align the marks made during dis-
m Main relief valve assembly :
assembly when assembling.
53.9 f 4.9 Nm 15.5 f 0.5 kgm}

Top cover Sr For details of assembly, see Assembly of

* If the top cover was removed during dis- main relief valve assembly.
assembly, install it as follows.
Fit O-ring to block end and install cover (54). 7. R.H. travel control valve 81 L.H. travel control
valve
QEI Mounting bolt :
Assemble the left and right travel control
31.85 + 2.45 Nm (3.25 f 0.25 kgm}
valves in the same way.

Cooler check valve

1) Assemble valve (36), then fit O-ring and
1) Fit O-ring and install plug (53).
install plug (35).
w Plug : 68.6 * 9.8 Nm {7 f 1 kgm}
w Plug:
56.35 + 7.35 NmI5.75 + 0.75 kgm}
2) Assemble valve (52) and spring (51), then
fit O-ring and install plug (50).
2) Assemble valve (34), piston (33) and
m Plug : 68.6 k 9.8 Nm {7 + 1 kgm} spring (32), then fit O-ring and install plug
(31).
Self pressure reducing valve
w Plug :
1) Assemble filter (49) to block, then fit O- 56.35 + 7.35 NmI5.75 + 0.75 kgm}
ring and install block (48).

QEI Mounting bolt : 3) Press fit 2 seals (30).

11.25 + 14.5 Nm (1.15 f 0.15 kgm}
4) Assemble spool (29).
2) Assemble spool (47) and spring (46). * Be careful to assemble in the correct
direction.
3) Fit O-ring and install pilot relief valve as-
sembly (45). 5) Assemble retainer (28). spring (27), and
retainer (26) to spool, then install bolt (25).
QEl Pilot relief valve assembly :
* Tighten the bolt with the spool as-
66.15 + 7.35 Nm (6.75 f 0.75 kgm}
sembled inside the valve.
Ir For details of assembly, see Assem-
m Bolt:
bly of pilot relief valve assembly.
8.35 + 1.45 Nm IO.85 + 0.15 kgm}

4) Assemble valve (44) and spring (431, then

6) Install plate (24) and case (23).
fit O-ring and install plug (42).
m Mounting bolt :
m Plug : 127.4 + 9.8 Nm (13 f 1 kgm}
11.25 _+1.45 Nm11.15 _+0.15 kgm1

Unload valve
7) Install plate (22).
Assemble spool (41) and spring (40), then fit
O-ring and backup ring, and install plug (39). w Mounting bolt :
11.25 + 1.45 Nmi1.15 + 0.15 kgm}
m Plug : 127.4 * 9.8 Nm {I3 + 1 kgm}

8. Boom control valve

Central safety valve
1) Assemble retainer (211, spring (20) and
Fit O-ring and backup ring, and install central
valve (19), then fit O-ring and install seat
safety valve assembly (38).
(19).
m Central safety valve assembly : 2) Fit O-ring and backup ring , then install
147 f IO Nm {I5 f 1 kgm) plug (17).

PC27 - 45MRX- 1 30-109

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

3) Fit O-ring, then install boom lock valve

(16).

m Mounting bolt :
11.25 k 1.45 Nm (1.15 + 0.15 kgm}

4) Fit O-ring and install 2 suction valve as-

semblies (15).

m Suction valve assembly :

53.9 f 4.9 Nm (5.5 f 0.5 kgm)

5) Assemble valve (14), then fit O-ring and

install plug (13).

w Plug :
56.35 f 7.35 Nm 15.75 f 0.75 kgm}

6) Assemble spring (12), valve (II), piston

(IO), and spring (9), then install plug (8).

m Plug :
56.35 + 7.35 Nm 15.75 * 0.75 kgm}

7) Assemble spool (7).

* Be careful to assemble in the correct
direction.

8) Assemble retainer (61, spring (5). and re-

tainer (4) to spool, then install bolt (3).

+ Tighten the bolt with the spool as-

sembled inside the valve.

m Bolt:
8.35 & 1.45 Nm (0.85 + 0.15 kgm)

9) Fit O-ring and install case (2) and (I ).

w Mounting bolt :
11.25 f 1.45 NmI1.15 + 0.15 kgm)

30-110 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

9. Arm control valve 3) Assemble valve (65) then fit O-ring and
1) Assemble valve (87) spring (86). then fit install plug (64).
O-ring and install plug (85).
w Plug :
m Plug : 56.35 f 7.35 Nm 45.75 f 0.75 kgm}
11.25 f 1.45 Nm Il.15 f 0.15 kgm)
4) Assemble spring (63), valve (62), piston
* Install 2 sets
(61), and spring (601, then fit O-ring and
2) Install suction valve assembly (84). install plug (59).

m Suction valve assembly : m Plug :

53.9 * 4.9 Nm 15.5* 0.5 kgm) 56.35 f 7.35 Nm i5.75 f 0.75 kgm}

3) Assemble valve (83) then fit O-ring and 5) Assemble spool (58).
install plug (82). * Be careful to assemble in the correct
direction.
w Plug :
56.35 + 7.35 Nm 15.75 It 0.75 kgm}
6) Assemble retainer (571, spring (561, and
retainer (55) to spool, then install bolt (54).
4) Assemble spring (81), valve (80), piston
* Tighten the bolt with the spool as-
(79), and spring (78), then fit O-ring and
sembled inside the valve.
install plug (77).
m Bolt:
m Plug :
8.35 f 1.45 Nm IO.85 + 0.15 kgml
56.35 5 7.35 Nm 15.75 * 0.75 kgm}

7) Fit O-ring and install case (53) and (52).

5) Assemble spool (76).
* Be careful to assemble in the correct QKI Suction valve assembly :
direction. 11.25 + 1.45 Nm (1.15 f 0.15 kgm}

6) Assemble retainer (75), spring (74). and 11. Swing control valve
retainer (73) to spool, then install bolt (72). 1) Assemble valve (51) and plug (501, then
* Tighten the bolt with the spool as- fit O-ring and install plug (49).
sembled inside the valve.
m Plug :
w Bolt: 11.25 + 1.45 Nm Il.15 + 0.15 kgm}
8.35 + 1.45 Nm IO.85 f 0.15 kgm}
2) Fit O-ring and install suction valve assem-
bly (48).
7) Fit O-ring and install case (71) and (70).
m Suction valve assembly :
m Suction valve assembly :
53.9 + 4.9 Nm 15.5 f 0.5 kgm)
11.25 rt 1.45 Nm {1.15+ 0.15 kgm)

3) Assemble valve (47), then fit O-ring and

10. Bucket control valve
install plug (46).
1) Assemble valve (69) spring (681, then fit m Plug :
O-ring and install plug (67).
56.35 + 7.35 Nm 15.75 + 0.75 kgm}
m Plug :
11.25 f 1.45 Nm Il.15 + 0.15 kgm) 4) Assemble spacer (451, valve (44), piston
(43) and springs (421, then fit O-ring and
* Install 2 sets
install plug (41).

2) Fit O-ring, then install suction valve as- w Plug :

sembly (66). 56.35 + 7.35 Nm i5.75 + 0.75 kgm}

B Suction valve assembly :

5) Press fit 2 seals (40).
53.9 f 4.9 Nm (5.5 * 0.5 kgm}

30-112 PC27 - 45MRX- 1

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

6) Assemble spool (39). 9) Assemble retainer (18), spring (17). and

t Be careful to assemble in the correct retainer (16) to spool, then install bolt (15).
direction. * Tighten the bolt with the spool as-
sembled inside the valve.
7) Assemble retainer (38), spring (371, and
w Bolt:
retainer (36) to spool, then install bolt (35).
8.35 k 1.45 Nm IO.85 f 0.15 kgm)
+ Tighten the bolt with the spool as-
sembled inside the valve.
IO) Fit O-rings and install plate (14) and case
m Bolt: (13).
8.35 + 1.45 Nm IO.85 + 0.15 kgm}
w Mounting bolt :
11.25 * 1.45 Nm (I.15 f 0.15 kgml
8) Install plate (34) and case (33).

w Mounting Bolt : 11) Fit O-ring and install plate (12) and case
11.25 k 1.45 Nm Il.15 + 0.15 kgm) (11).
w Mounting bolt :
9) Install plate (32).
11.25 + 1.45 Nm Il.15 + 0.15 kgm)

12. Blade & breaker control valve

1) Assemble valve (31) and spring (30), then 13. Swing control valve
fit O-ring and install plug (29).
1) l&all block (IO).
w Plug :
m Mounting bolt :
11.25 f 1.45 Nm Il.15 f 0.15 kgm)
11.25 + 1.45 Nm Il.15 f 0.15 kgm)

2) Fit O-ring and install suction valve assem- 2) Assemble spool (9)
bly (28).
* Be careful to assemble in the correct
w Suction valve assembly : direction.
53.9 f 4.9 Nm I5.5 f 0.5 kgml
3) Assemble retainer (8), spring (71, and re-
3) Fit O-ring and install block (27). tainer (6) to spool, then install bolt (5).
* Tighten the bolt with the spool as-
w Mounting bolt :
sembled inside the valve.
11.25 f 1.45 Nm (1.15 * 0.15 kgm)
m Bolt:
4) Fit O-ring and install plug (26). 8.35 k 1.45 Nm (0.85 + 0.15 kgm)

m Plug :
4) Fit O-ring and install case (4) and (3).
53.9 + 4.9 Nm t5.5 f 0.5 kgml
w Mounting bolt :
5) Press fit 2 seals (25). 11.25 + 1.45 Nm Il.15 f 0.15 kgm)

6) Assemble spool (24). 14. Top cover portion

Ir Be careful to assemble in the correct 1) Fit O-ring, then install 2 plugs (2).
direction.
2) Fit O-ring and backup ring and install plug
7) Assemble retainer (231, spring (22), and (I).
retainer (21) to spool, then install bolt (20).
w Plug : 39.2 f 4.9 Nm I4 * 0.5 kgm)
* Tighten the bolt with the spool as-
sembled inside the valve.

w Bolt:
8.35 f 1.45 Nm (0.85 + 0.15 kgm1

8) Install plate (19).

-k Be careful to assemble in the correct
direction.

PC27 - 45MRX- 1 30-113

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

DISASSEMBLY OF MAIN RELIEF VALVE

ASSEMBLY
t To make the set pressure the same as before dis-
assembly, set the protrusion from the nut of the
adjustment screw to the dimension measured
before disassembly.
After installing the control valve assembly to the
machine, check the set pressure again. For de-
tails, see TESTING AND ADJUSTING.

Assemble spring (91, valve (8) and sleeve (IO) then

secure with ring (7).

Assemble poppet (6) and spring (51, then fit O-

ring and install screw (4).

Install nut (3).

m Nut : 68.7 + 9.8 Nm (7 + 1 kgml

Install O-ring (I) and backup ring (2).

CKP03132

DISASSEMBLY OF PILOT RELEIFE VALVE

ASSEMBLY
Sr To make the set pressure the same as before dis-
assembly, set the protrusion from the nut of the
adjustment screw to the dimension measured
before disassembly.
After installing the control valve assembly to the
machine, check the set pressure again. For de-
tails, see TESTING AND ADJUSTING.

1. Assemble poppet (7), washer (6) and spring (5)

from sleeve (8), then fit O-ring and install screw 6
(4).

2. Install nut (3).

3. Install O-ring (1) and backup ring (2).

CKP03133

30-114 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

* Do not remove the long connecting bolt at the

bottom of the control valve. 5) Remove plug (28), then remove spring
Remove the short connecting bolt at the top (29) and poppet (30).
of the control valve when adding a service
valve. 6) Remove spool (31).
* The spools and pressure compensation valves
(both the flow control valves and reducing 7) Remove plug (321, then remove spring
valves) are not interchangeable between (33) and poppet (34).
blocks, so be sure to mark them when disas-
sembling. 8) Remove plug (351, then remove seat (36)
* Do not remove the plug at the end of the and ball (37).
spool.
* The pressure of the central safety valve can- 9) Remove spool (38).
not be set when it is mounted on the machine,
so do not disassemble it. IO) Remove 2 seals (39).

1. Top cover 11) Remove plug (40).

1) Remove plug (I).
* In some cases there is pressure re- 12) Remove block (41).
maining in the central safety valve cir-
cuit, so loosen the plug slowly. 13) Remove suction valve assembly (42) and
+ Remove the O-ring and backup ring. blade RISE relief nvalve (I 14)

2) Remove 2 plugs (2). 14) Remove plug (431, then remove spring
(44) and plug (45).
2. Swing control valve
1) Remove cases (31, (4) and retainer (5). 4. Swing control valve
1) Remove cases (46) and plate (47).
2) Remove bolt (6).
* Loosen the bolt with the spool still as- 2) Remove bolt (48).
sembled inside the valve. * Loosen the bolt with the spool still as-
sembled inside the valve.
3) Remove retainer (7). spring (8), retainer
(9), plug (IO), spring (I I) and poppet (12). 3) Remove retainer (49), spring (50), and re-
tainer (51).
4) Remove plug (13), then remove spring
(14) and poppet (15). 4) Remove plug (521, then remove spring
(53) and poppet (54).
5) Remove spool (16).
5) Remove plug (551, then remove spring
6) Remove block (17). (56) and poppet (57).

7) Remove swing relief valve assembly (18). 6) Remove spool (58).

3. Blade & breaker control valve 7) Remove 2 seals (59).

I) Remove cases (19) and plate (20).
8) Remove plug (601, then remove spring
2) Remove plug (21), then remove case (22) (61), piston (62), valve (631, and spacer
and plate (23). (64).

3) Remove bolt (24). 9) Remove plug (651, then remove orifice (66)
* Loosen the bolt with the spool still as- and valve (67).
sembled inside the valve.
IO) Remove suction valve assembly (68).
4) Remove retainer (251, spring (29), and re-
tainer (27).

30-116 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

11) Remove plug (69). 9) Remove plug (Ill), then remove spring
(112) and valve (113).
12) Remove plug (70). then remove spring * Remove 2 sets
(71) and valve (72).

5. Bucket control valve

1) Remove cases (73), (74) and retainer (75).

2) Remove bolt (76).

* Loosen the bolt with the spool still as-
sembled inside the valve.

3) Remove retainer (77), spring (78). and re-

tainer (79).

4) Remove plug (80).

5) Remove spool (81).

6) Remove plug (82). then remove spring

(83), piston (84), valve (85). and spring
(86).

7) Remove plug (87), then remove plug (88)

and valve (89).

8) Remove 2 suction valve assemblies (90).

9) Remove plug (91), then remove spring

(92) and valve (93).
* remove 2 sets

6. Arm control valve

1) Remove cases (94), (95) and retainer (96).

2) Remove bolt (97).

+ Loosen the bolt with the spool still as-
sembled inside the valve.

3) Remove retainer (98), spring (99). and re-

tainer (100).

4) Remove plug (101).

5) Remove spool (102).

6) Remove plug (103), then remove spring

(104). piston (105), valve (106), and spring
(107).

7) Remove plug (108), then remove valve

(109).

8) Remove suction valve assembly (110).

PC27 - 45MRX-1 30-117

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

MAIN CONTROL VALVE BOTTOM (Z/2)

‘20
3
J
79
l

:
.J
%9

bd J756

107-4, 1
O e---l03
OlO44
106 4

CWPO7402

30-118 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

7. Boom control valve 5) Remove plug (51), then remove spring

1) Remove cases (I), (2) and retainer (3). (52).

2) Remove bolt (4). 6) Remove 6 screws (53).

or Loosen the bolt with the spool still as-
sembled inside the valve. 7) Remove block (54).

3) Remove retainer (5), spring (6), and re- 8) Remove plug (55), then remove spring
tainer (7). (52), piston (57) and valve (58).
* Remove O-ring and backup ring.
4) Remove plug (8).
9) Remove plug (59), then remove spring
5) Remove plug (9), then remove spring (IO) (60) and valve (61).
and poppet (II).
9. Central safety valve
6) Remove spool (12). Remove central safety valve assembly (62).
* Remove the O-ring and backup ring.
7) Remove plug (13), then remove spring
(14). piston (15), valve (16) and spring (17). 10. L.H. travel control valve
1) Remove plug (63), then remove valve (64).
8) Remove plug (18), then remove valve (19).
2) Remove plug (65), then remove spring
9) Remove 2 suction valve assemblies (20). (66) and valve subassembly (67).

10) Remove plate (21) and screw (22). 3) Remove case (68) and plate (69).

11) Remove spring (23). seat (24), valve (25) 4) Remove bolt (70).
and plug (26).
5) Remove washer (71), retainer (72). spring
12) Remove sleeve (27), ring (28). piston (29) (73), retainer (74) and 2 seals (75).
and spring (30).
* Remove O-ring and backup ring from 6) Remove 2 suction valve assemblies (76).
sleeve (27).
11. Junction valve
13) Remove plug (31) and screw (32). 1) Remove plug (77).

14) Remove valve block (33). 2) Remove plug (78), then remove plug (79)
and valve (80).
15) Remove plug (34). * Remove 2 sets
* Remove the O-ring and backup ring.
3) Remove plug (81), then remove spring
16) Remove seat (35). valve (36), spring (37) (82) and valve (83).
and retainer (38). t Remove 2 sets

8. Throttle valve 4) Remove plug (84). then remove spring

1) Remove plug (30). (40) and (41), then re- (85) and washer (86).
move spool (42), spring (43) and valve
(44). 5) Remove plug (87), then remove plug (88),
ring (89) and screw (90).
2) Remove plug (45).
6) Remove spool (91).
3) Remove screw (46), plug (47), and ring
(48). 7) Remove plug (92), then remove ring (93).

4) Remove plug (49), then remove spool (50). 8) Remove plug (94). then remove ring (95).

PC27 - &MN- 1 30-119

a
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

9) Remove screw (96), plug (97) and ring (98). 14. Cooler bypass valve
I) Remove plug (1331, then remove spring
IO) Remove plug (99), then remove poppet (134) and valve (135).
(IOO), spool (101) and spring (102).
2) Remove plug (136), then remove spring
11) Remove plug (103). (137) and valve (138).

12) Remove plug (104), then remove ring 15. Top cover
(105). Ir When adding a service valve, remove
cover (139).
13) Remove plug (106), then remove ring
(107). 16. Coupling bolt (When adding a service valve)
Jr When adding a service valve, disassemble
14) Remove screw (108). as follows.

15) Remove 2 screws (109). 1) Remove 4 coupling bolts (140) from up-
per main control valve.
16) Remove 2 plugs (1 IO).

17) Remove 4 screws (11 I).

18) Remove block (112).

19) Remove plug (113).

20) Remove plug (114), then remove spring

(115) and valve (116).
+ Remove 2 sets

12. Main relief valve

Remove main relief valve assembly (117).
+ For detail of assembly, see Assembly of
main relief valve assembly.

13. R.H. travel control valve

1) Remove plug (1181, then remove valve
(119).

2) Remove plug (120), then remove spring

(121).

3) Remove spool (122).

4) Remove case (123) and plate (124).

5) Remove bolt (125).

6) Remove washer (1261, retainer (1271,

spring (128), retainer (129) and 2 seals
(130).

7) Remove spool (131).

8) Remove 2 suction valve assemblies (132).

30-120 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

DISASSEMBLY OF MAIN RELIEF VALVE

ASSEMBLY
1. Remove O-ring (I) and backup ring (2).

2. Remove adjustment nut (3) and lock nut (4).

3. Remove spacer (51, then remove spring (6) and

poppet (7).

4. Remove plug (8).

5. Remove seal (9) and plug (8).

6. Remove seat (1 I), piston (121, spring (13) and pop-

pet from sleeve (IO).

7. Remove poppet (14) from seal (15).

0
-2
-1
CWPO7393

PC27 - 45MRX- 1 30-121

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

* The spools and pressure compensation valves 4) Install plate (124) and case (123).
(both the flow control valves and reducing
m Mounting bolt :
valves) are not interchangeable between
9.8 - 12.7 Nm Il.0 - 1.3 kgm)
blocks, so align the marks made during dis-
assembly when assembling.
5) Assemble spool (122) and spring (121),
then fit O-ring and install plug (120).
1. Coupling bolt (When adding a service valve)
* When adding a service valve, assemble w Plug :
as follows. 24.5 - 34.3 Nm i2.5 - 3.5 kgm)

1) Install service valve assembly. 6) Assemble valve (119), then fit O-ring and
install plug (118).
2) Tighten 4 coupling bolts at upper main
w Plug : 47 - 58.8 Nm (4.8 - 6.0 kgm)
control valve.

m Coupling bolt :
29.4 - 34.3 Nm I3.0 - 3.5 kgml 5. Main relief valve
Fit O-ring and install main relief valve assem-
2. Top cover bly (117).
+ If the top cover was removed during dis-
m Main relief valve assembly :
assembly, install it as follows.
49 - 58.8 Nm I5.0 - 6.0 kgml
Fit O-ring to block end and install cover (139).
Ir For details of assembly, see Assembly of
N Mounting bolt :
main relief valve assembly.
29.4 - 34.3 Nm 13.0 - 3.5 kgm}

6. Junction valve
3. Cooler bypass valve
1) Assemble valve (116) and spring (115),
1) Assemble valve (138) and spring (137), then fit O-ring and install plug (I 14).
then fit O-ring and install plug (136).
* Install 2 sets.
w Plug :
117.6 - 161.8 NmI12.0 - 16.5 kgm) 2) Fit O-ring and install plug (I 13).

m Plug : 47 - 58.8 NmI4.8 - 6.0 kgm)

2) Assemble valve (135) and spring (134),
then fit O-ring and install plug (133).
3) Install block (I 12).
w Plug :
m Mounting bolt :
117.6 - 161.8 Nm112.0 - 16.5 kgm)
9.8 - 12.7 Nm il.0 - 1.3 kgml

4. R.H. travel control valve

4) Install 4 screws (I 11).
1) Fit O-ring, then install 2 suction valve as-
sembly(132).
5) Fit O-ring and install 2 plugs (110).
w Suction valve assembly :
w Plug :
39.2 - 49 Nm t4.0 - 5.0 kgm)
19.6 - 24.5 Nm 12.0 - 2.5 kgm)

2) Assemble spool (131).

6) Install 2 screws (109).
Sr Be careful to assemble in the correct
direction.
7) Install screw (108).

3) Assemble 2 seals (130), retainer (129),

8) Assemble ring (107), then fit O-ring and
spring (128), retainer (127) and washer
install bracket (106).
(126) to spool, then install bolt (125).
* Tighten the bolt with the spool as-
9) Assemble ring (105), then fit O-ring and
sembled inside the valve.
install bracket (104).
B Bolt : 6.9 - 9.8 Nm IO.7 - 1.0 kgm)
10) Fit O-ring and install plug (103).

PC27 - 45MRX- 1 30-123

a
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

11) Assemble spring (102). spool (101) and 4) Assemble valve subassembly (67) and
poppet (IOO), then fit O-ring and install spring (66), then fit O-ring and install plug
plug (99). (65).

w Plug : 47 - 58.8 Nm I4.8 - 6.0 kgm}

12) Assemble ring (981, plug (97) and screw
(96). Assemble valve (64). then fit O-ring and
5)
install plug (63).
13) Assemble ring (951, then fit O-ring and
install plug (94). w Plug : 47 - 58.8 Nm I4.8 - 6.0 kgm}

14) Assemble ring (931, then fit O-ring and Central safety valve
install plug (92). Fit O-ring and install central safety valve as-
sembly (62).
15) Assemble spool (91).
m Central safety valve assembly :
Ir Be careful to assemble in the correct
137 -157 Nm I14.0 - 16.0 kgm}
direction.

Throttle valve
16) Assemble screw (9OL ring (89) and plug
I) Assemble valve (61) and spring (60), then
(88), then fit O-ring and install plug (87).
fit O-ring and install plug (59).

17) Assemble washer (86) and spring (851, w Plug :

then fit O-ring and install plug (84). 19.6 - 24.5 Nm I2.0 - 2.5 kgm}

18) Assemble valve (83) and spring (82). then 2) Assemble valve (58). piston (57) and
fit O-ring and install plug (81). spring (561, then fit O-ring, backup ring
* Install 2 sets. and install plug (55).

19) Assemblevalve (80), then install plug (79). 3) Install block (54).

m Plug : m Mounting bolt :

1.3 - 1.7 Nm (0.13 - 0.17 kgm} 9.8 - 12.7 Nm {I.0 - 1.3 kgm}
* Install 2 sets.
4) Press fit 6 screws (53).
20) Fit O-ring, then install 2 plugs (78).
5) Assemble spring (52), then fit O-ring and
Q!z Plug : 47 - 58.8 Nm 14.8 - 6.0 kgml
install plug (51).

21) Fit O-ring, then install plug (77).

6) Assemble spool (50). then fit O-ring and
m Plug : install bracket (49).
19.6 - 24.5 Nm I2.0 - 2.5 kgm}
7) Assemble ring (48). then fit O-ring and in-
7. L.H. travel control valve stall plug (47).
1) Fit O-ring, then install 2 suction valve as-
sembly(76). 8) Install screw (46).

m Suction valve assembly :

9) Install plug (45).
39.2 - 49 Nm I4.0 - 5.0 kgm}

IO) Assemblevalve (44), spring (43) and spool

2) Assemble 2 seals (75), retainer (74), spring (421, then install plug (41).
(73), retainer (72) and washer (71), then
install bolt (70).
11) Fit O-ring and install plug (40).
m Bolt:9.8-12.7Nm{l.O-1.3kgm)
12) Fit O-ring and install plug (39).
3) Install plate (69) and case (68).
w Plug :
w Bolt:9.8-12.7Nm{l.O-1.3kgmI 19.6 - 24.5 Nm t2.0 - 2.5 kgm}

30-124 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

10. Boom control valve 15) Fit O-ring and install plug (8).
1) Assemble retainer (38), spring (37) and
valve (36) and seat (35). 16) Assemble retainer (7). spring (6), and re-
tainer (5), then fit O-ring and install bolt
2) Fit O-ring and backup ring, then install (4).
plug (34). * Tighten the bolt with the spool as-
sembled inside the valve.
3) Install valve block (33).
m Bolt : 6.9 - 9.8 Nm IO.7 - 1.0 kgml

4) Install screw (32).

17) Assemble retainer (3), then install case (2).

5) Fit O-ring, then install plug (31). B Mounting bolt :

9.8 - 12.7 Nm {IO. - 1.3 kgml
w Plug :
24.5 - 34.3 Nm 12.5 - 3.5 kgm}
18) Install case (1).

6) Fit spring (30), piston (29), ring (28L O-ring QEI Mounting bolt :
and backup ring then assemble sleeve 9.8 - 12.7 Nm Il.0 - 1.3 kgm)
(27).

7) Install plug (26).

m Plug :
1.3 - 1.7 Nm IO.13 - 0.17 kgml

8) Install valve (25), seal (24) and spring (23).

9) Install screw (22) and plate (21).

QEI Mounting bolt :

3.9 - 5.9 Nm IO.4 - 0.6 kgm}

IO) Fit O-ring, then install suction valve as-

sembly (20).

w Suction valve assembly :

39.2 - 49 Nm 14.0 - 5.0 kgml

11) Assemble valve (19), then fit O-ring and

install plug (18).

w Plug : 47 - 58.8 Nm 14.8 - 6.0 kgml

12) Assemble spring (17), valve (16), piston

(15) and spring (14), then fit O-ring and
install plug (13).

13) Assemble spool (12).

Ir Be careful to assemble in the correct
direction.

14) Assemble poppet (11 )and spring (IO),then

fit O-ring and install plug (9).

N Plug :
14.7 - 19.6 Nm Il.5 - 2.0 kgml

& Plug : Gasket sealant

(Lock tight No. 638 or equivalent)

PC27 - 45MRX- 1 30-125

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

MAIN CONTROL VALVE TOP (l/Z)

CWPO7401

30-126 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

11. Arm control valve 12. Bucket control valve

1) Assemble valve (113) and spring (112). 1) Assemble valve (93) and spring (92), then
then fit O-ring and install plug (111). fit O-ring and install plug (91).

m Plug : w Plug :
19.6 - 24.5 Nm I2.0 - 2.5 kgm} 19.6 - 24.5 Nm 12.0 - 2.5 kgm)

* Install 2 sets. * Install 2 sets.

2) Fit O-ring and install suction valve assem- 2) Fit O-ring and install suction valve assem-
bly (110). bly (90).

w Suction valve assembly : w Suction valve assembly :

39.2 - 49 Nm t4.0 - 5.0 kgm) 39.2 - 49 Nm (4.0 - 5.0 kgm)

3) Assemble valve (log), then fit O-ring and 3) Assemblevalve (89), then install plug (88).
install plug (108).
m Plug :
m Plug : 47 - 58.8 Nm f4.8 - 6.0 kgm) 1.3 - 1.7 Nm IO.13 - 0.17 kgm)

4) Assemble spring (107), valve (106), piston 4) Fit O-ring and install plug (87).
(105) and spring (104), then fit O-ring and
m Plug : 47 - 58.8 Nm I4.8 - 6.0 kgm)
install plug (103).

m Plug : 47 - 58.8 Nm 14.8 - 6.0 kgm) 5) Assemble spring (86), valve (85). piston
(84) and spring (83), then fit O-ring and
5) Assemble spool (102). install plug (82).
* Be careful to assemble in the correct
w Plug : 47 - 58.8 Nm f4.8 - 6.0 kgm)
direction.

6) Assemble spool (81).

6) Fit O-ring, then install plug (101).
* Be careful to assemble in the correct
m Plug : direction.
14.7 - 19.6 Nm (1.5 - 2.0 kgm)
7) Fit O-ring, then install plug (80).
& Plug : Gasket sealant
(Lock tight No. 638 or equivalent) w Plug :
14.7 - 19.6 Nm Il.5 - 2.0 kgm)
7) Assemble retainer (IOO), spring (99), and
& Plug : Gasket sealant
retainer (98), then fit O-ring and install bolt
(Lock tight No. 638 or equivalent)
(97).
Ir Tighten the bolt with the spool as-
8) Assemble retainer (79), spring (78), and
sembled inside the valve.
retainer (77), then fit O-ring and install bolt
w Bolt : 6.9 - 9.8 Nm IO.7 - 1 .O kgm) (76).
Ir Tighten the bolt with the spool as-
8) Assemble retainer (96), then install case sembled inside the valve.
(95). w Bolt : 6.9 - 9.8 Nm (0.7 - 1.0 kgm)
w Mounting bolt :
9.8 - 12.7 Nm Il.0 - 1.3 kgm) 9) Assemble retainer (75). then install case
(74).
9) Install case (94).
w Mounting bolt :
m Mounting bolt : 9.8 - 12.7 Nm (1.0 - 1.3 kgm)
9.8 - 12.7 Nm fl.0 - 1.3 kgm)
10) Install case (73).

w Mounting bolt :
9.8 - 12.7 Nm (1.0 - 1.3 kgm)

PC27 - ISMRX- 1 30-127

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

13. Swing control valve 11) Install plate (47) and case (46).
1) Assemble valve (72) and spring (71), then w Mounting Bolt :
fit O-ring and install plug (70).
9.8 - 12.7 Nm (1.0 - 1.3 kgm)
w Plug :
19.6 - 24.5 Nm (2.0 - 2.5 kgm} 14. Blade 81 breaker control valve
1) Assemble valve (45) and spring (44), then
2) Fit O-ring and install plug (69). fit O-ring and install plug (43).

m Plug : 39.2 - 49 Nm I4.0 - 5.0 kgm) m Plug :

24.5 - 34.3 Nm (2.5 - 3.5 kgm}
3) Fit O-ring and install suction valve assem-
bly (68). 2) Install suction valve assembly (42) and
blade RISE relief valve (114).
m Suction valve assembly :
39.2 - 49 Nm (4.0 - 5.0 kgm} m Suction valve assembly l
blade RISE relief valve assembly :
4) Assemble valve (67) and orifice (66). then 39.2 - 49 Nm (4.0 - 5.0 kgm}
fit O-ring and install plug (65).
3) Install block (41).
m Plug : 47 - 58.8 Nm (4.8 - 6.0 kgm}

4) Fit O-ring and install plug (40).

5) Assemble spacer (64). valve (63), piston
(62) and springs (62), then fit O-ring and w Plug : 39.2 - 49 Nm (4.0 - 5.0 kgm}
install plug (60).
5) Assemble 2 seals (39).
m Plug : 47 - 58.8 Nm (4.8 - 6.0 kgm}

6) Assemble spool (38).

6) Assemble 2 seals (59).
* Be careful to assemble in the correct
direction.
7) Assemble spool (58).
* Be careful to assemble in the correct
7) Assemble ball (37) and seat (36), then fit
direction.
O-ring and install plug (35).

8) Assemble poppet (57) and spring (56), m Plug :

then fit O-ring and install plug (55). 14.7 - 19.6 Nm II.5 - 2.0 kgm)

m Plug : & Plug : Gasket sealant

14.7 - 19.6 Nm (1.5 - 2.0 kgm} (Lock tight No. 638 or equivalent)

& Plug : Gasket sealant

8) Assemble poppet (34) and spring (33),
(Lock tight No. 638 or equivalent)
then fit O-ring and install plug (32).

9) Assemble poppet (54) and spring (53), m Plug :

then fit O-ring and install plug (52). 14.7 - 19.6 Nm (1.5 - 2.0 kgm)

Plug : & Plug : Gasket sealant

14.7 - 19.6 Nm {I .5 - 2.0 kgm} (Lock tight No. 638 or equivalent)
Plug : Gasket sealant
(Lock tight No. 638 or equivalent) 9) Assemble spool (31).
* Be careful to assemble in the correct
IO) Assemble retainer (51), spring (50), and direction.
retainer (49), then install bolt (48) with
washer. 10) Assemble poppet (30) and spring (29),
* Tighten the bolt with the spool as- then fit O-ring and install plug (28).
sembled inside the valve.
m Plug : 14.7 - 19.6 Nm (1.5-2.0 kgm}
m Bolt : 9.8 - 12.7 Nm (1.0 - 1.3 kgm}
& Plug : Gasket sealant
(Lock tight No. 638 or equivalent)

30-128 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

11) Assemble retainer (27). spring (26), and 6) Assemble retainer (91, spring (8), and re-
retainer (25), then install bolt (24) with tainer (7), then fit O-ring and install bolt
washer. (6).
Ir Tighten the bolt with the spool as- + Tighten the bolt with the spool as-
sembled inside the valve. sembled inside the valve.

m Bolt : 9.8 - 12.7 Nm (I.0 - 1.3 kgml m Bolt : 6.9 - 9.8 Nm {0.7 - 1 .O kgm}

12) Install plate (23) and case (22). 7) Install plate (5) and case (4).

QEI Mounting bolt : QEI Mounting bolt :

9.8 - 12.7 Nm {I .O - 1.3 kgm} 9.8 - 12.7 Nm Il.0 - 1.3 kgm}

13) Fit O-ring and install plug (21). 8) Install case (3).

w Plug : QEI Mounting bolt :

19.6 - 24.5 Nm I2.0 - 2.5 kgm} 9.8 - 12.7 Nm il.0 - 1.3 kgm}

14) Install plate (20) and case (19). 16. Top cover portion
1) Fit O-ring, then install 2 plugs (2).
m Mounting bolt :
9.8 - 12.7 Nm Il.0 - 1.3 kgm} m Plug :
19.6 - 24.5 Nm I2.0 - 2.5 kgml
15. Swing control valve
1) Fit O-ring and install swing relief valve as- 2) Fit O-ring and backup ring, then install
sembly (18). plug (I).

w Swing relief valve assembly : m Plug :

39.2 - 49 Nm I4.0 - 5.0 kgm} 34.3 - 44.1 Nm (3.5 - 4.5 kgm}

2) Install block (17).

QEI Mounting bolt :

9.8 - 12.7 Nm Il.0 - 1.3 kgm)

3) Assemble spool (16)

Ir Be careful to assemble in the correct
direction.

4) Assemble poppet (15) and spring (141,

then fit O-ring and install plug (13).

m Plug :
14.7 - 19.6 Nm II.5 - 2.0 kgm)

& Plug : Gasket sealant

(Lock tight No. 638 or equivalent)

5) Assemble poppet (12) and spring (II),

then fit O-ring and install plug (IO).

m Plug :
14.7 - 19.6 Nm Il.5 - 2.0 kgm}

& Plug : Gasket sealant

(Lock tight No. 638 or equivalent)

PC27 - 45MRX- 1 30-129

0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

ASSEBBLY OF MAIN RELIEF VALVE

ASSEMBLY
1. Assemble seat (15) to poppet (14). @-3
2. Assemble poppet(l41, spring (131, piston (12) and
w--’
seat (I 1) to sleeve (IO).
o-5 0

3. Install seal (9) to plug (8). It---5

w-7
4. Install plug (8) to sleeve (IO).
Q
m Plug : 78 - 98 Nm (8 - 10 kgm)
0
5. Assemble poppet (71, spring (6) and spacer (5). -8
- II
6. Install lock nut (4) and adjusting nut (3). 12
IF-
a Remove oil then coat liquid adhesive (di- b 13
lute sealend 242 or equivalent to 20 % with
IF-14
alcohol) on adjusting nut, and install it.
I5
m Lock nut : 39 - 49 Nm I4.0 - 5.0 kgm)
IO
m Adjusting nut : 39 - 49 Nm {4.0- 5.0 kgm}

7. Install O-ring (I) and backup ring (2).

0
-2
-1
CWPO7393

30-130 PC27 - 45MRX- 1

a
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT LEFT PPC VALVE

REMOVAL OF WORK
EQUIPMENT LEFT PPC VALVE
ASSEMBLY
(FOR ARM, SWING CONTROL)
PC27MRX, PCBOMRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Disconnect the cable from the negative (-1 ter-
minal of the battery.
CUP06491

1. I3isconnect boot (I) from connecting port, then

out it into case (4).
2. 1qemove cover (21, then disconnect working lamp
\Niring connector (P8) from switch.
3. Iqemove 4 mounting bolts (3), then remove case
(4).
4. IDisconnect PPC valve outlet hose (5) and inlet
Ilose (6).
5. IDisconnect arm IN hose (7).
6. Iqemove PPC valve 3 mounting bolts (8).
7. IIsconnect swing LEFT hose (9).
8. IDisconnect arm DUMP hose (IO).
9. IDisconnect swing RIGHT hose (II), then remove
Ieft PPC valve assembly (12).

INSTALLATION OF WORK
EQUIPMENT LEFT PPC VALVE
ASSEMBLY
(FOR ARM, SWING CONTROL)
PC27MRX, PCSOMRX

Carry out installation in the reverse order to re-

moval.

Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

Bleeding air
Bleed the air from PPC valve assembly. For de-
tails, see TESTING AND ADJUSTING, Bleeding
air.

PC27 - 45MRX- 1 30-l 31

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT LEFT PPC VALVE

REMOVAL OF WORK
EQUIPMENT LEFT PPC VALVE
ASSEMBLY
(FOR ARM AND SWlNG CONTROL)
PC35MRX, PC40MRX, PC45MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
g ground and stop the engine.
Drsconnect the cable from the negative (-) ter-
minal of the battery.

1. Disconnect boot (I) from cover, then remove le-

ver (2). m
2. Disconnect wiring connector (3), (4), (51, then re-
move cover (6).
Wiring connector (3) (P9), (4) (P7), (5) (P8) :
(PC35MRX)
Wiring connector (3) (M181, (4) (S7), (5) (S6) :
(PC4OMRX, PC45MRX)
* For canopy specification machine, disconnect
wiring connector (S6) or (P8) (5) alone.
3. Disconnect 6 hoses (6). m
4. Remove left PPC valve assembly (7).

INSTALLATION OF WORK
EQUIPMENT LEFT PPC VALVE
ASSEMBLY
(FOR ARM AND SWING CONTROL)
PC35MRX, PC40MRX, PC45MRX
l Carry out installation in the reverse order to re-
moval.

E-i-

& Lever thread : Thread tightener (LT-2)

t The hoses are marked with tie wrap, so align

show in under.
. Port P : Red and green
. Port T : Blue and white
. Port PI : Green PA

. Port P2 : Orange 1
. Port P3 : Blown
. Port P4 : White

m Port P, Port T joint bolt :

34.3 - 44.1 Nm I3.5 - 4.5 kgm}

l Refilling with oil (hydraulic tank)

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.

w Filler plug (PC35MRX) : CWPO7371

181.3 - 240.1 Nm 118.5 - 24.5 kgm}

30- 132 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT RIGHT PPC VALVE

REMOVAL OF WORK
EQUIPMENT RIGHT PPC VALVE
ASSEMBLY
(FOR BOOM AND BUCKET
CONTROL)
PC27MRX, PCSOMRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
AI Disconnect the cable from the negative (-1 ter-
minal of the battery.

1. Disconnect boot (1) from connecting port, then

put it into case (4).
2. Remove nut, then put the starting switch (2) into
case.
3. Remove 4 mounting bolts (31, then remove case
(4).
* Disconnect connector (PI) from monitor.
4. Disconnect PPC valve outlet hose (5) and inlet
hose (6).
5. Disconnect boom LOWER hose (7).
6. Disconnect horn switch wiring connector (8) (P3).
7. Remove PPC valve 3 mounting bolts (9).
8. Disconnect bucket CRUL hose (IO). ---. DXP01004
9. Disconnect boom RISE hose (I 1).
10. Disconnect bucket DUMP hose (12), then remove
right PPC valve assembly (13).

INSTALLATION OF WORK
EQUIPMENT RIGHT PPC VALVE
ASSEMBLY
(FOR BOOM AND BUCKET
CONTROL)
PC27MRX, PC30MRX

l Carry out installation in the reverse order to re-

moval.

l Refilling with oil (hydraulic tank)

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.

l Bleeding air
Bleed the air from PPC valve assembly. For de-
tails, see TESTING AND ADJUSTING, Bleeding
air.

PC27 - 45MRX-1 30- 133

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT RIGHT PPC VALVE

REMOVAL OF WORK
EQUIPMENT RIGHT PPC VALVE
ASSEMBLY
(FOR BOOM AND BUCKET
CONTROL)
PC35MRX, PC40MRX, PC45MRX
a Stop the machine on the horizontal ground, then
lower the work equipment completely to the
ground and stop the engine.
a Disconnect the cable from the negative (-1 ter-
minal of the battery.

1. Disconnect boot (1) from cover, then remove le-

ver (2). m
2. Disconnect wiring connector (P3) (PC35MRX),(Sl)
(PC40MRX, PC45MRX) (3).
3. Move cover (4) to upper side.
4. Disconnect 6 hoses (5). m
5. Remove right PPC valve assembly (6).

INSTALLATION OF WORK
EQUIPMENT RIGHT PPC VALVE
ASSEMBLY
(FOR BOOM AND BUCKET
CONTROL)
PC35MRX, PC40MRX, PC45MRX
l Carry out installation in the reverse order to re-
moval.

Ir Install the lever not to twist the wire.

* The hoses are marked with tie wrap, so align

show in under.
l Port P : Red and green (PC35MRX)
: Yellow and black
(PC40MRX, PC45MRX)
l Port T : Blue and white (PC35MRX)
: Orange and blown
(PC40MRX, PC45MRX)
l Port PI : Yellow P4

l Port P2 : Black
l Port P3 : Red
l Port P4 : Blue

m Port P, Port T joint bolt :

34.3 - 44.1 Nm (3.5 - 4.5 kgm}

l Refilling with oil (hydraulic tank)

Add oil through the oil fillerto the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

m Filler plug (PC35MRX) :

181.3 - 240.1 Nm (18.5 - 24.5 kgm}

30- 134 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE

DISSASEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Remove
(3).
nut (I), then remove disc (2) and boot
i’zY---’
2. Remove bolt, then remove plate (5).
+ Do not remove joint (4) without exchange
time.

3. Remove seal (6) and collar (7).

4. Remove piston (81, then remove retainer (9),

spring (lO),(ll) and shim (12).
+ Spring (IO) is assembled 2 kind of springs
which differ the installed losd. Be sure the
mounting position (hydraulic pressure port)
and fit tag to distinguish them.
There are 2 types of spring, so check the
mounting position.

5. Remove valve (13) from body (14).

&---
0
8

CEP00424

PC27 - 45MRX- 1 30-135

a
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE

ASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Assemble valve (13) in body (14).

2. Assemble shim (12) and spring (11) to valve (13).

* Spring (1 I) is not symmetrical at the top and
bottom, so assemble with the small coil di-
ameter (inside diameter) atthe shim (12) end.

3. Assemble spring (IO), retainer (9), and piston (8).

* There are some kind of spring which differ
the free length, so be careful when assem-
bling.
Spring free length
Port position
(mm)
PI lP2
(PC27MRX, PC30MRX) 50.35

PI P2 (PC35MRX.
l

47.93
PC40MRX, PC45MRX)

P3 l P4 44.45

+ There are port position impressed mark un-

der of the valve body.

& Piston : Grease (GZ-Ll)

* Coat the grease outside diameter of piston

and inside diameter of body, when assem-
bling piston (8).

4. Fit O-ring to collar (7) and assemble in body (14),

then install seal (6).

5. Assemble plate (5).

w Mounting bolt :
13.2 ? 1.5 Nm (I.35 IL 0.15 kgm}

6. Install joint (4).

& Sliding portion of joint : Grease (G2-Ll)

& Body thread : Thread tightener (LT-2)

* Drop thread tightner on each 2 position of

thread as shown indrawing.

m Joint : 44.1 + 4.9 Nm I4.5 k 0.5 kgm}

* Keep the tightening torque.

7. Assemble hoot(3) and disc (2), then tighten with

nut(l).

w Nut : 112.8 + 14.7 Nm (11.5 f 1.5 kgm}

* Adjust the disc height, after assembled the

disc. For details, see TESTING AND
ADJUSTTING, Adjusting PPC valve.

30- 136 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

REMOVAL OF BOOM CYLINDER

ASSEMBLY
PC27MRX, PCBOMRX
A Stop the machine on the horizontal ground, then
lower the work equipment completely to the
ground and stop the engine.

1. Remove cover (I).

2. Sling boom cylinder assembly, then remove head
pin (2). a
* There are shims installed, check the number,
thickness and insalled position.
CWPO6554
* Start engine, and retract piston rod.
3. Disconnect head hose (3) and bottom hose (4).
* After disconnection fit a blind plug.
4. Remove bottom pin (51, then remove boom cyl-
inder assembly (6). m

& tn Boom cylinder assembly : 25kg

INSTALLATION OF BOOM
CYLINDER ASSEMBLY
PC27MRX, PC30MRX
l Carry out installation in the reverse order to re-
moval.

(g When aligning the position of the pin hole,

never insert your fingers in the pin hole.

a Inside surface of bushing :

Anti-friction compound (G2-T)

Ir Adjust the shim thickness so that the clear-

ance (a + b)between boom mounting portion
and cylinder head is below 1 mm.
l Standard shim thickness : 1.0 mm

m ‘-\i
a b
CWPO6466
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.

& Inside surface of bushing :

Anti-friction compound (G2-T)

+ Adjust the shim thickness so that the clear-

ance (a + bjbetween swing bracket and cylin-
der bottom mounting portion is below 1 mm.

l Refilling with oil (hydraulic tank)

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.

l Bleeding air
Bleed the air from the boom cylinder. For details,
&,A CWPO6468

see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX 1 30- 137

0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

REMOVAL OF BOOM CYLINDER

ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

g Startengine and extend the arm and bucketfully,

then lower the work equipment completely to
the ground.

1. Remove cover (I).

2. Slinn boom cylinder assembly, then remove head

pin (2). . m
j, There are shims installed, check the number,
thickness and insalled position.

A Start engine, and retract piston rod, then tie

piston rod with wire to prevent it from com-
ing out.
a Release the remaining pressure in the hy-
drauliccircuit. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure
in hydraulic circuit.

3. Disconnect 2 hoses (3) from boom cylinder as-

sembly.
* After disconnection fit a blind plug.

4. Remove bottom pin (41, then remove boom cyl-

inder assembly (5). @I
* There are shims installed, check the number,
thickness and insalled position.

L+kg Boom cylinder assembly :

30kg (PC35MRX)
40 kg (PC40MRX, PC45MRX)

30-138 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

INSTALLATION OF BOOM
CYLINDER ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-PI CWP07398

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

-k Adjust the shim thickness so that the clear-

ance a between boom cylinder (5) head and
boom (6).
l Clearance a : Below 1.0 mm
l Standard shim thickness : 1 .O mm

11

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling : CWPO7399

Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

Ir Adjust the shim thickness so that the clear-

ance b between boom cylinder (5) head and
swing bracket (7). (PC35MRX)
l Clearance b : Below 1.0 mm
l Standard shim thickness : 1 .O mm

l Refilling with oil (hydraulic tank)

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.

QKI Filler plug (PC35MRX) :

181.3 - 240.1 Nm I18.5 - 24.5 kgm}

l Bleeding air
Bleed the air from the boom cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30- 139

0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER

REMOVAL OF ARM CYLINDER

ASSEMBLY
PC27MRX, PC30MRX

a Start the engine, extend the arm cylinder to just

before the end of its stroke, then set the arm on
top of stand 0, then lower the bucket link to the
ground.

Sling arm cylinder assembly, then remove head

pin (1). m
* There are shims installed, check the number,
thickness and insalled position.
* Start engine, and retract piston rod.
Disconnect head hose (2), bottom hose (3) and
clamp (4).
* After disconnection fit a blind plug.
Remove bottom pin (51, then remove arm cylin-
der assembly (6). m

kg
L&l Arm cylinder assembly : 25kg

INSTALLATION OF ARM
CYLINDER ASSEMBLY
PC27MRX, PCSOMRX
l Carry out installation in the reverse order to re-
moval.

g When aligning the position of the pin hole,

never insert your fingers in the pin hole.

6 Inside surface of bushing :

Anti-friction compound (GZ-T)

J, Adjust the shim thickness so that the clear-

ance (a + bjbetween arm mounting portion
and piston head is below 1 mm.
l Standard shim thickness : 1 .O mm
/w
CWPO6556
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.

6 Inside surface of bushing :

Anti-friction compound (G2-T)

-k Adjust the shim thickness so that the clear-

ance (a + bjbetween arm mounting portion
and cylinder bottom mounting portion is be-
low 1 mm.

l Refilling with oil (hydraulic tank)

Add oil through the oil fillerto the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
l Bleeding air
Bleed the air from the boom cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air.

30- 140 PC27 - 45MRX-1

DISASSEMBLY AND ASSEMBLY ARM CYLINDER

REMOVAL OF ARM CYLINDER

ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

A Start the engine, extend the arm cylinder to just

before the end of its stroke, then set the arm on
top of stand 0, then lower the bucket link to the
ground.

1. Sling arm cylinder assembly, then remove head

pin (1). m
* There are shims installed, check the number,
thickness and insalled position.

A Start engine, and retract piston rod, then tie

piston rod with wire to prevent it from com-
ing out.

A Release the remaining pressure in the hy-

draulic circuit. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure
from hydraulic circuit.

2. Disconnect 2 hoses (2) from arm cylinder assem-

bly.
* After disconnection fit a blind plug.

3. Remove bottom pin (3), then remove arm cylin-

der assembly (4). m
* There are shims installed, check the number,
thickness and insalled position.

+I kg Arm cylinder assembly : 30 kg (PC35MRX)

35 kg (PC40MRX)
40 kg (PC45MRXI

PC27 - 45MRX-1 30-141

a
DISASSEMBLY AND ASSEMBLY ARM CYLINDER

INSTALLATION OF ARM CYLIN-

DER ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-P)

a Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance a between arm cylinder (4) head and arm
(5).
l Clearance a : Below 1 .O mm
l Standard shim thickness : 1.0 mm
a

g When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

CWPO7362
Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance b between arm cylinder (4) head and
boom (6).
l Clearance b : Below 1.0 mm
l Standard shim thickness : 1.0 mm

l Refilling with oil (hydraulic tank)

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.

B Filler plug (PC35MRX) :

181.3 - 240.1 Nm I18.5 - 24.5 kgm}

l Bleeding air
Bleed the air from the arm cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air.

30 142 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

REMOVAL OF BUCKET CYLIN-

DER ASSEMBLY
PC27MRX, PC30MRX
g Stop the machine on the horizontal ground, set
the bottom of bucket horizontal, then lower the
bucket completely to the ground and stop the
engine.

1. Set block @ under link and arm.

2. Sling bucket cylinder assembly, then remove head
pin (1). m
* There are shims installed, check the number,
thickness and insalled position. CWPO6560

* Start engine, and retract piston rod.

3. Disconnect head hose (2), bottom hose (3) and
clamp (4).
* After disconnection fit a blind plug.
4. Remove bottom pin (5), then remove bucket cyl-
inder assembly (6). m

INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
PC27MRX, PCBOMRX CWPO6561

l Carry out installation in the reverse order to re-

moval.

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Inside surface of bushing :

Anti-friction compound (G2-T)

Ir Install shims certainly.

g When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Inside surface of bushing :

Anti-friction compound (G2-T)

* Adjust the shim thickness so that the clear-

ance (a + b)between arm mounting portion
and cylinder bottom mounting portion is be-
low 1 mm.

l Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

. Bleeding air
Bleed the air from the boom cylinder. For details, CWPO6563
see TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

REMOVAL OF BUCKET
CYLINDER ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

a Stop the machine on the horizontal ground, set

the bottom of bucket horizontal, then lower the
bucket completely to the ground and stop the
engine.

1. Set block @_Iunder link and arm.

2. Sling boom cylinder assembly, then remove head

pin (1). jn
Sr There are shims installed, check the number,
thickness and insalled position.

a Start engine, and retract piston rod, then tie

piston rod with wire to prevent it from com-
ing out.

A Release the remaining pressure in the hy-

draulic circuit. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure
from hydraulic circuit.

3. Disconnect 2 hoses (2) from bucket cylinder as-

sembly.
Sr After disconnection fit a blind plug.

4. Remove bottom pin (3), then remove bucket cyl-

inder assembly (4). 112
* There are shims installed, check the number,
thickness and insalled position.

&I kg Bucket cylinder assembly :

30 kg (PC40MRX)
35 kg (PC45MRX)

30- 144 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

INSTALLATION OF BUKET
CYLINDER ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

g When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

l Standard shim thickness :

2.5 mm (Right and Left)

g When aligning the position of the pin hole,

never insert your fingers in the pin hole.
5
& Pin sliding surface, when assembling :
Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

Ir Adjust the shim thickness so that the clear-

ance a between bucket cylinder (4) bottom and
arm (5).
l Clearance a : Below 1.0 mm
CWPO7363
l Standard shim thickness : 1 .O mm

. Refilling with oil (hydraulic tank)

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.

m Filler plug (PC35MRX) :

181.3 - 240.1 Nm j18.5 - 24.5 kgm}

l Bleeding air
Bleed the air from bucket cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX-1 30- 145

0
DISASSEMBLY AND ASSEMBLY SWING CYLINDER

REMOVAL OF SWING
CYLINDER ASSEMBLY
PC27MRX, PC30MRX

a Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
1. Remove head pin (1). m
* There are shims installed, check the number,
thickness and insalled position.
* Start engine, and retract piston rod.
2. Disconnect head hose (2).
Ir After disconnection fit a blind plug.
3. Remove hydraulic tank and fuel tank. For details, CWP06664 5. CWPO6565
see REMVAL OF HYDRAULIC TANK AND FUEL
TANK ASSEMBLY
4. Disconnect bottom side hose (3).
5. Disconnect grease tube (4).
6. Remove lock plate (5), then remove bottom side
pin (6). m

&I kg Swing cylinder assembly : 25kg

INSTALLATION OF SWING
CYLINDER ASSEMBLY
PC27MRX, PC30MRX
l Carry out installation in the reverse order to re-
moval.

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Inside surface of bushing : a

Anti-friction compound (G2-T)

* Adjust the shim thickness so that the clear-

ance (a + blbetween swing cylinder head and
swing bracket is below 1 mm. b

g When aligning the position of the pin hole,

never insert your fingers in the pin hole.

&Inside surface of bushing :

Anti-friction compound (G2-T)

+ Adjust the shim thickness so that the clear-

ance (c + dlbetween revolving frame mount-
ing portion and cylinder bottom mounting
portion is below 1 mm.
l Refilling with oil (hydraulic tank)
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.
l Bleeding air
CWP06566
Bleed the air from the swing cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air.

30- 146 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY SWING CYLINDER

REMOVAL OF SWING
CYLINDER ASSEMBLY
PC35MRX

a Swing revolving frame SOAKto right, then ex-

tend the swing cylinder to just before the end of
its stroke, then lower the work equipment bucket
link to the ground completely and stop the en-
gine.

1. Open right upper cover, then remove right and

right lower cover.

2. Remove hydraulic lower cover (1).

3. Remove cylinder head pin (2). m

* There are shims installed, check the number,
thickness and insalled position.

4. Disconnect 2 hoses (2) from swing cylinder as-

sembly.
* After disconnection fit a blind plug.

5. Disconnect grease hose (4) at bottom pin, then

remove grease fitting (5).

PC27 - ISMRX-1
DISASSEMBLY AND ASSEMBLY SWING CYLINDER

6. Remove cylinder head pin (6). m

* There are shims installed, check the number,
thickness and insalled position.

7. Lift off swing cylinder assembly (7).

Ir It keep well balance when remained in extend
position.

Akg Swing cylinder assembly : 40kg

30-148 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY SWING CYLINDER

INSTALLATION OF SWING
CYLINDER ASSEMBLY
PC35MRX

l Carry out installation in the reverse order to re-

moval.

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance a between swing cylinder (7) head and
swing bracket (8).
l Clearance a : Below 1.0 mm
l Standard shim thickness : 1 .O mm

g When aligning the position of the pin hole,

never insert your fingers in the pin hole.

6 Pin sliding surface, when assembling : CWPO7334

Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

Ir Adjust the shim thickness so that the clear-

ance b between swing cylinder (7) bottom and
revolving frame (9).
l Clearance b : Below 1.0 mm
l Standard shim thickness : 1 .O mm
b’

l Refilling with oil (hydraulic tank)

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. CWPO7335

B Filler plug (PC35MRX) :

181.3 - 240.1 Nm 118.5 - 24.5 kgm}

l Bleeding air
Bleed the air from swing cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-149

0
DISASSEMBLY AND ASSEMBLY SWING CYLINDER

REMOVAL OF SWING
CYLINDER ASSEMBLY
PC40MRX, PC45MRX

A Swing revolving frame 90” to right, then extend

the swing cylinder to just before the end of its
stroke, then lower the work equipment bucket
link to the ground completely and stop the en-
gine.

1. Remove radiator and hydraulic cooler assembly.

For details, see REMVAL OF RADIATOR AND HY-
DRAULIC COOLER ASSEMBLY.

2. Remove cylinder head pin (I). a

* There are shims installed, check the number,
thickness and insalled position.

3. Disconnect 2 hoses (2) from swing cylinder as-

sem bly.
-k After disconnection fit a blind plug.

4. Disconnect cylinder bottom pin (3). m

* There are shims installed, check the number,
thickness and insalled position.

5. Lift off swing cylinder assembly (4).

&I kg Swing cylinder assembly : 45kg

30- 150 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY SWING CYLINDER

INSTALLATION OF SWING
CYLINDER ASSEMBLY
PC40MRX, PC45MRX

l Carry out installation in the reverse order to re- 5

moval.

/I

g When aligning the position of the pin hole,

never insert your fingers in the pin hole.

&& Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-PI CWPO
7381

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance a between swing cylinder (4) head and
swing bracket (5).
l Clearance a : Below 1.0 mm
l Standard shim thickness : 1.0 mm
m
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.

6 Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-P)

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance b between swing cylinder (4) bottom and
revolving frame (6).
l Clearance b : Below 1.0 mm
l Standard shim thickness : 1 .O mm

l Refilling with oil (hydraulic tank)

Add oil through the oil fillerto the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

l Bleeding air
Bleed the air from swing cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-l 51

0
DISASSEMBLY AND ASSEMBLY BLADE CYLINDER

REMOVAL OF BLADE CYLINDER

ASSEMBLY
PC27MRX, PC30MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove blade cylinder guard (1).

2. Remove blade cylinder bottom pin (2). a
* There are shims installed, check the number,
thickness and insalled position. CWPO6608

3. Start engine, and retract piston rod.

A Stop engine and release the remaining pres-

sure in piping. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure
from hydraulic circuit.
4. Disconnect head hose (3) and bottom hose (4).
* After disconnection fit a blind plug.
5. Remove head pin (5), then remove blade cylinder
assembly (6). m

&I k# Blade cylinder assembly : 25kg

I k==s- CWPO6609

INSTALLATION OF BLADE
CYLINDER ASSEMBLY
PC27MRX, PC30MRX
l Carry out installation in the reverse order to re-
moval.

,$& Inside surface of bushing :

Anti-friction compound (G2-TI

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

Ir Install shim certainly.

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.

Ir Install shim certainly.

l Refilling with oil (hydraulic tank)

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.
l Bleeding air
Bleed the air from the blade cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air.

30-152 PC27 - 45M RX- 1

0
DISASSEMBLY AND ASSEMBLY BLADE CYLINDER

REMOVAL OF BLADE CYLINDER

ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

A Swing revolving frame 90’ to right, then lower

the work equipment blade to the ground com-
pletely and stop the engine.

1. Remove blade cylinder cover (1).

2. Sling blade cylinder, then remove head pin (2).

m
* There are shims installed, check the number,
thickness and insalled position.

A Start the engine, and react the piston rod.

a Operate the blade control lever several times

to release the remaining pressure in hydrau-
lic circuit.

3. Disconnect 2 hoses (3).

4. Remove bottom pin (41, then lift off blade cylin-

der assembly (5). m
* If there are shims installed, check the num-
ber and thickness and installed position.

r;7kg Swing cylinder assembly :

25 kg (PC35MRX)
30 kg (PC40MRX, PC45MRX)

PC27 - 45MRX-1
DISASSEMBLY AND ASSEMBLY BLADE CYLINDER

INSTALLATION OF BLADE
CYLINDER ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

6 Pin sliding surface, when assembling :

CWPO7350
Molybdenum disulphide grease (LM-PI

a Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance a between blade cylinder (5) head and
track frame (6).
l Clearance a : Below 1.0 mm
l Standard shim thickness : 1.0 mm

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance a between blade cylinder (5) bottom
blade (7).
l Clearance a : Below 1.0 mm
l Standard shim thickness : 1.0 mm

Refilling with oil (hydraulic tank)

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.

w Filler plug (PC35MRX) :

181.3 - 240.1 Nm (18.5 - 24.5 kgmj

Bleeding air
Bleed the air from blade cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air.

30-154 PC27 - 45MRX- 1

a
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Pipe
Disconnect the pipes from the cylinder.

2. Piston Rod Assembly

1) Set the cylinder assembly (1) to the tool Ul.

2) Loosen the cylinder head using the tool U2.

u
CLPO3114

3) Remove the piston rod assembly (2) from the

cylinder.

3. Piston Assembly
I) Setthe piston rod assembly (2) to the tool Ul.

2) Remove the piston nut (4) using the tool U3.

* Width across flats of piston nut:
(mm)
Model Boom Arm Bucket Swing Blade

PC27MRX 46 46 36 41 46

9
PC3OMRX 46 46 46 41 46

PC35MRX 46 50 46 55 50

PC40MRX 55 55 46 55 55
CLPO3116
PC45MRX 1 55 1 55 1 46 1 55 I 55

3) Remove the piston assembly (5) from the pis-

ton rod (6).

CKP0311;

PC27 - 45MRX-1 30-155

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

4) Disassemble piston assembly as follows.

i) Remove wear ring (7) from piston (8).
ii) Remove piston ring (9).

CKPO311 a

5) Remove cushion plunger (IO) from piston rod

(6).
* Boom cylinder only

CKP03119

4. Cylinder head assembly

1) Remove cylinder head assembly (I 1) from pis-
ton rod (6).

CKP03120

2) Disassemble cylinder head assembly as fol-

lows.
i) Remove O-ring (12) and 2 backup rings
(13) from cylinder head (14).
* Boom cylinder only
ii) Remove O-ring (15) and backup ring (16).
iii) Using snap ring pliers, remove snap ring
(17).
iv) Remove dust seal (18).
v) Remove rod packing (19).
vi) Remove bushing (20). (Except boom cyl-
inder) II l3 I2 I3 CKP03121

30-156 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

5. Piston rod
I) Remove 2 dust seals (21) from piston rod (6).
2) Remove bushing (22).

CKP03122

6. Cylinder
I) Remove 2 dust seals (23) from cylinder (3).
2) Remove bushing (24).
3) Remove elbow(25).
* Arm cylinder for PC35MRX only

CKP0312

PC27 - 45MRX-1
30-157
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Cylinder
1) Fit O-ring and install elbow (25) to cylinder
(3).
t Arm cylinder for PC35MRX only
* Install with the tip of the elbow facing the
cylinder head.

w Elbow : 785 f 78.5 Nm {SO * 8.0 kgml

CKP03123

2) Press fit bushing (24).

3) Press fit 2 dust seals (23).

2. Piston rod
1) Press fit bushing (22) to piston rod (6).
2) Press fit 2 dust seals (21).

CKP03122

3. Cylinder head assembly

I) Assemble cylinder head assembly as follows.
i) Using tool U4, press fit bushing (20) to cyl-
inder head (14).
ii) Using tool U5, press fit dust seal (18).

CKP03124 CKP03125

iii) Using snap ring pliers, install snap ring

(17).
iv) Install rod packing (19).
v) Install O-ring (15) and backup ring (16).
Ir Align the direction of installation with
the diagram on the right.
vi) Install O-ring (12) and 2 backup rings (13).
* Boom cylinder only

l3 I2 l3 CKP03126

30-158 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

2) Fit O-ring and install cylinder head assembly

(11) to piston rod (6).

CKP03120

4. Piston assembly
1) Install cushion plunger (IO) to piston rod (6).
-k Boom cylinder only

CKP03119

2) Assemble piston assembly as follows.

i) Using tool U6, expand piston ring (9).
* Set the piston ring on tool U6 and turn
the handle 8 to 10 times to expand the
ring.
ii) Install piston ring (9) to piston (8).
iii) Using tool U7, compress piston ring (9).
iv) Install wear ring (7).

CKP03127
9W8 CKP03129

3) Install piston assembly (5) to piston rod (6).

CKP03117

PC27 - 45MRX- 1 30-159

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

4) Set piston rod assembly (2) to tool Ul.

5) Using tool U3, install piston nut (4).
t Width across flats of piston nut : (mm)

& Piston nut : Thread tightener

9 CLPO3lIG

(Loctite 262 or equivalent)

m Piston nut : See table below

5. Piston rod assembly

I) Install piston rod assembly (2) to cylinder (3).
2) Set cylinder assembly (I) to tool Ul.
3) Using tool U2, tighten cylinder head.

QEI Cylinder head : See table below

6. Piping
Install cylinder piping.

m Sleeve nut : 29.4 - 68.6 Nm {3.0 - 7.0 kgm}

* PC35MRX Arm cylinder, boom cylin-

der and swing cylinder
PC40MRX. PC45MRX Swing cylinder
PC35MRX Bucket cylinder (multi
change specification head side)

w sleeve nut :
Ir 49 + 19.6 Nm t5.0 ? 2.0 kgm}
PC35MRX Bucket cylinder (bottom
side)

m sleeve nut :
* 58.8 - 98.1 Nm 16.0 - 10.0 kgm}
CLPO3114
PC27MRX Arm cylinder
PCSOMRX, PC35MRX Bucket cylinder
(bottom side)
PC45MRX Boom cylinder

w sleeve nut :
+ 127.5 f 19.6 Nm {I3 f 2 kgm}
PCIOMRX, PC45MRX Bucket cylinder

w sleeve nut :
Sr 107.9 - 166.7 Nm {II - 17 kgm}
PC45MRX Arm cylinder

30-160 PC27 - 45MRX- 1

Cc
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

w Piston nut tightening torque :

(Nm (kgm1)
Model Boom Arm Bucket Swing Blade
785k78.5 785i78.5 412?41 647k64.5 785k78.5
PC27MRX
(8ort81 (8W8} (4ti4.21 (66&6.6} (80f81
785+78.5 785k78.5 785k78.5 647k64.5 785k78.5
PC30MRX
{88M81 {8&s} (8M81 (66k6.6) (80&8)
785k78.5 1,250+130 785k78.5 1,670&170 1.08oi110
::;;-;I 1 (8oi81 ~~,2.7’ (SO*81 ,l7OW 1 (llO?ll)
1,250fl30 1,42ofl40 1,080~110 1,67Ml70 1.42Ml40
{127+12.7} {145+14.5} {llO~ll) (170?17) I145k14.5)
1.250~130 1,670?170 1,080~110 1,67Ml70 1,420+_140
PC45MRX (127+12.7) (170+17} {IlMll) (170fl7} (145+14.5]

QE Cylinder head tightening torque :

(Nm Ikgm))
Model 1 Boom 1 Arm 1 Bucket 1 Swing I Blade
569&57 785k78.5 637k63.5 588?59 588k58.8
PC27MRX (58k5.81 (8&8) (65rf6.5) (60?6) (m6)
569f57 676.W67.1 49ort49 588159 588k58.8
PC30MRX
(58k5.8) (69+6.9) (5&5} (6oi6) I6ort61
677k67.7 677k67.5 735i73.5 735573.5
PC35MRX 7:;;;
(69?6.9) (6W6.91 (75k7.5) (75k7.5)
PC40MRX 676567.6 726k72.6 735k73.5 676.2k67.6 863k86.5
(69?6.9) (74k7.4) (75k7.5) (6W6.9) (88k8.8)
676k67.6 863k86.3 735k73.5 735k73.5 863k86.5
PC45MRX (6W6.9} (88k8.8) (75k7.51 (75F7.5) (88+8.8)

PC27 - 45MRX-1 30-161

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

REMOVAL OF WORK
EQUIPMENT ASSEMBLY
PC27MRX, PCSOMRX
g Stop the machine on the horizontal ground, then
extend the arm and bucket fully, lower the work
equipment completely to the ground and stop
the engine.
g Disconnect the cable from the negative (-) ter-
minal of the battery.
Disconnect hose (1) to boom cylinder, hose (2) to
arm cylinder and hose (3) to bucket cylinder.
Disconnect working lamp wiring connector (4)
(M25, M26).
CWPO6560 CWPO6681
Remove head pin (5), then Lower boom cylinder
assembly onto block 0. m
* There are shims installed, check the number,
thickness and insalled position.
Remove pin (7), then lift off boom assembly(8).
Izl
Ir Using a lever block 0, adjust the balanceof
work equipment, and lift off.
* There are shims installed, check the number,
thickness and insalled position.

r+lke Work equipment assembly :

310 kg (PC27MRX)
330 kg (PC30MRX)

INSTALLATION OF WORK uJCWPO6582

EQUIPMENT ASSEMBLY
PC27MRX, PC30MRX
l Carry out installation in the reverse order to re-
moval.

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.
& Bushing inside surface :
Anti-friction compound (G2-T)
li Adjust the shim thickness so that the clear-
ance (a + b)between swing cylinder head and a b
arm mounting portion is below 1 mm. CWPO6466

rzz

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.
& Bushing inside surface :
Anti-friction compound (G2-T)
* Adjust the shim thickness so that the clear-
ance (c + d)between boom mounting portion
and swing bracket mounting portion is below
0.5 mm.
. Refilling with oil (hydraulic tank)
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.
l Bleeding air
Bleed the air from work equipment. For details, I ---b CWP06579

see TESTING AND ADJUSTING, Bleeding air.

30-162 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

REMOVAL OF WORK
EQUIPMENT ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

a Stop the machine on the horizontal ground, then

extend the arm and bucket fully, lower the work
equipment completely to the ground and stop
the engine.
a Release the remaining pressure in the hydraulic
circuit. For details, see TESTING AND ADJUST-
ING, Releasing remaining pressure in hydraulic
circuit.
A Disconnect the cable from the negative
minal of the battery.
(-) ter-

1. Disconnect front lamp connector (1).

* Disconnect wiring clamp also.

2. Disconnect hose clamp (2).

3. Sling the boom cylinder assembly (3), then re-

move head pin (4). a
* There are shims installed, check the number
and thickness and installed position.
A After removing, start engine and retract pis-
ton rod, then lower it on blade.

4. Disconnect 4,hoses (5).

Sr Breaker specification machine, remove 2
hoses for breaker.

5. Remove bracket (6).

6. Sling the work equipment assembly, then remove

boom foot pin (7). m
* There are shims installed, check the number
and thickness and installed position.

7. Lift off work equipment assembly.

& kg Work equipment assembly :

300 kg (PC35MRXI
420 kg (PC40MRX)
450 kg (PC45MRX)

PC27 - 45MRX-1 30-163

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.

6 Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-P)

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance between boom cylinder (3) head and
boom (9) is below Imm.
l Standard shim thickness : 1.0 mm

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-P)

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

l Refilling with oil (hydraulic tank)

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.

w Filler plug (PC35MRX) :

181.3 - 240.1 Nm (18.5 - 24.5 kgm)

l Bleeding air
Bleed the air from arm cylinder and bucket cylin-
der. For details, see TESTING AND ADJUSTING,
Bleeding air.

30-164 PC27 - 45MRX- 1

a
DISASSEMBLY AND ASSEMBLY BUCKET

REMOVAL OF BUCKET ASSEMBLY

PC27MRX, PC30MRX

A Stop the machine on the horizontal ground, then

extend the arm and bucket fully, lower the work
equipment completely to the ground and stop
the engine.

Remove lock bolt (I), then remove connection pin

(2) between link and bucket. m

Rise the boom slowly, then remove 4 O-ring (3)

and disconnect arm and bucket assembly (4).

& kg Bucket assembly : 50 kg (PC27MRX)

65 kg (PC30MRX)

INSTALLATION OF BUCKET
ASSEMBLY CWPO6513

PC27MRX, PC30MRX

l Carry out installation in the reverse order to re-

moval.

* When installing lock bolt, tighten the lock bolt

when loosen alittle.
* At installing the O-ring, install O-ring to link
and arm end side, then assemble it while work
equipment operating.
* Be careful not to catch your fingers or O-ring.

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

PC27 - 45MRX-1 30-165

0
DISASSEMBLY AND ASSEMBLY BUCKET

REMOVAL OF BUCKET ASSEMBLY

PC35MRX, PC4OMRX, PC45MRX

A Stop the machine on the horizontal ground, set

the bottom of bucket horizontal, then lower the
bucket completely to the ground and stop the
engine.

1. Remove lock bolt and nut (I), then remove link

pin (2) between link and bucket. m

&L Start the engine and retract bucket cylinder.

2. Remove lock bolt and nut (3), then remove arm

top pin (4). jn

3. Remove bucket assembly (5).

a Start the engine and rise work equipment

slowly, then disconnect bucket assembly
from arm.

& kg Bucket assembly : 80 kg (PC35MRX)

110 kg (PC40MRX)
120 kg (PC45MRX)

INSTALLATION OF BUCKET
ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.

a Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-P)

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the clearance between lock bolt l nut

(I), (3) and bucket (5) a, b is 1 to 2 mm.

30-166 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY ARM

REMOVAL OF ARM ASSEMBLY

PC27MRX, PC30MRX

A Stop the machine on the horizontal ground, then

lower the blade completely to the ground and
stop the engine.
1. Remove bucket assembly. For details, see RE-
MOVAL OF BUCKET ASSEMBLY
2. Lower the arm assembly on block @ and 0.
3. Set block@ between arm cylinder and boom, then
remove head pin (I). m
+ There are shims installed, check the number,
thickness and insalled position.
4. Start the engine and retract the piston of arm cyl-
UJ CWPO6569 CWPO6570

inder (2).
5. Disconnect hose (3) and (4) for bucket cylinder.
t After disconnection fit a blind plug.
6. Remove pin (5), then raise boom slowly and dis-
connect arm assembly (6). m
* There are shims installed, check the number,
thickness and insalled position.
& kg Arm assembly :
75 kg (PC27MRX. PC30MRX)

INSTALLATION OF ARM
ASSEMBLY CWPO6571

PC27MRX, PCSOMRX
l Carry out installation in the reverse order to re-
moval.
m

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.
& Bushing inside surface :
Anti-friction compound (G2-T)
* Adjust the shim thickness so that the clear-
ance (a + blbetween swing cylinder head and
arm mounting portion is below 1 mm.

m CWPO6556

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.
& Bushing inside surface :
Anti-friction compound (G2-T)
* Adjust the shim thickness so that the clear-
ance (c + djbetween boom mounting portion
and swing bracket mounting portion is below
1 mm.
. Refilling with oil (hydraulic tank)
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
. Bleeding air
Bleed the air from bucket cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-167

0
DISASSEMBLY AND ASSEMBLY ARM

REMOVAL OF ARM ASSEMBLY

PC35MRX, PC40MRX, PC45MRX

1. Remove bucket assembly. For details, see RE-

MOVAL OF BUCKET ASSEMBLY

2. Tie link to arm with wire.

3. Set arm on block 0.

A Start the engine, pull in the arm to just be-

fore the end of its stroke, then lower the arm
on top of block 0.

4. Set block @ between arm cylinder and boom,.

5. Remove arm cylinder head pin (1). m

* There are shims installed, check the number
and thickness and installed position.

a Start engine and retract arm cylinder.

A Release the remaining pressure in the hy-

drauliccircuit. For details,seeTESTlNG AND
ADJUSTING, Releasing remaining pressure
from hydraulic circuit.

6. Disconnect 2 hoses (2).

* lncase of breaker specification machine, dis-
connect 2 hoses for breaker also.

7. Remove boom top pin (3). m

* There are shims installed, check the number
and thickness and installed position.

8. Remove arm assembly (4).

A Start engine, then raise the boom slowly and

disconnect the arm assembly and boom.

&I kg Arm assembly : 75 kg (PC35MRX)

110 kg
(PC40MRX, PC45MRX)

30-168 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY ARM

NSTALLATION OF ARM
ASSEMBLY
PC35MRX, PCQOMRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

6 Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-P)

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

+ Adjust the shim thickness so that the clear-

ance a between arm cylinder (5) head and arm
(4).
l Clearance a : Below 1.0 mm
l Standard shim thickness : 1 .O mm

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling : I CWPO7337

Molybdenum disulphide grease (LM-P)

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance b between arm (4) head and boom (6).
l Clearance b : Below 0.5 mm
l Standard shim thickness : 0.5 mm

l Refilling with oil (hydraulic tank)

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.
CWPO733F
m Filler plug (PC35MRX) :
181.3 - 240.1 Nm 118.5 - 24.5 kgm}

l Bleeding air
Bleed the air from bucket cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX- 1 30-169

0
DISASSEMBLY AND ASSEMBLY BUCKET, ARM

REMOVAL OF BUCKET, ARM

ASSEMBLY
PC27MRX, PCSOMRX
a Stop the machine on the horizontal ground, then
lower the blade completely to the ground and
stop the engine.
1. Start engine, then operate bucket cylinder to the
end of its stroke and arm cylinder to a point just
before the end of its stroke, and lower the arm on
top of block 0.
2. Set block @ between arm cylinder and boom, then
remove head pin (I). m
* There are shims installed, check the number, d CWPO5573 1 1 CWPO6574
thickness and insalled position.
3. Start the engine and retract the piston of arm cyl-
inder (2).
4. Disconnect hose (3) and (4) for bucket cylinder.
j, After disconnection fit a blind plug.
5. Remove pin (5), then raise boom slowly and dis-
connect arm, bucket assembly (6). m
* There are shims installed, check the number,
thickness and insalled position.

&I kg Arm, bucket assembly :

150 kg (PC27MRX)
170 kg (PCBOMRX)

CWPO6575

INSTALLATION OF BUCKET,
ARM ASSEMBLY
J I
PC27MRX, PC30MRX
. Carry out installation in the reverse order to re-
moval.
m
a When aligning the position of the pin hole,
never insert your fingers in the pin hole.
& Bushing inside surface :
Anti-friction compound (G2-T)
+ Adjust the shim thickness so that the clear-
ance (a + bjbetween swing cylinder head and
CWPO6556
arm mounting portion is below 1 mm.
m
a When aligning the position of the pin hole,
never insert your fingers in the pin hole.
& Bushing inside surface :
Anti-friction compound (G2-T)
Ir Adjust the shim thickness so that the clear-
ance (c + dlbetween boom mounting portion
and swing bracket mounting portion is below
1 mm.
l Refilling with oil (hydraulic tank)
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.
l Bleeding air
Bleed the air from bucket cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air.

30-170 PC27 - 45MRX- 1

a
DISASSEMBLY AND ASSEMBLY BUCKET, ARM

REMOVAL OF BUCKET, ARM

ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

a Start engine, then operate bucket cylinder to the

end of its stroke and arm cylinder to a point just
before the end of its stroke, and lower the arm
on top of block 0.

1. Set block@ between arm cylinder and boom, then

remove head pin (I).

2. Remove head pin (I). m

+ There are shims installed, check the number,
thickness and insalled position.

& Start engine and retract arm cylinder.

A Release the remaining pressure in the hy-

draulic circuit. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure
from hydraulic circuit.

3. Disconnect 2 hoses (2).

* lncase of breaker specification machine, dis-
connect 2 hoses for breaker also.

4. Remove boom top pin (3). a

+ There are shims installed, check the number,
thickness and insalled position.

5. Remove bucket, arm assembly (4).

A Start engine, then raise the boom slowly and

disconnect the bucket, arm assembly and
boom.

&I kg Bucket, arm assembly : 160 kg (PC35MRX)

210 kg (PC4OMRX)
230 kg (PC45MRX)

PC27 - 45MRX-1 30-171

Cc
DISASSEMBLY AND ASSEMBLY BUCKET, ARM

INSTALLATION OF BUKET, ARM

ASSEMBLY
PC35MRX, PC4OMRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-P)

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance a between arm cylinder (5) head and arm
(4).
l Clearance a : Below 1.0 mm
l Standard shim thickness : 1.0 mm

121
----._--L_
g When aligning the position of the pin hole,
never insert your fingers in the pin hole. 'r--------Y
& Pin sliding surface, when assembling : I CWPO7337

Molybdenum disulphide grease (LM-P)

6 Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance b between arm (4) head and boom (6).
l Clearance b : Below 0.5 mm
l Standard shim thickness : 0.5 mm

l Refilling with oil (hydraulic tank)

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.
CWPO7338
m Filler plug (PC35MRX) :
181.3 - 240.1 Nm 118.5 - 24.5 kgm}

l Bleeding air
Bleed the air from bucket cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air.

30-172 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY SWING BRACKET

REMOVAL OF SWING BRACKET

ASSEMBLY
PC27MRX, PC30MRX

A Stop the machine on the horizontal ground, then

lower the blade completely to the ground and
stop the engine.
A Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove work equipment bucket assembly. For

details, see REMOVAL OF WORK EQUIPMENT
ASSEMBLY
2. Remove boom cylinder bottom pin (I), then re-
move boom cylinder assembly 0. m

&I k@ Boom cylinder assembly : 25 kg

* There are shims installed, check the number,
thickness and insalled position.
3. Remove lock plate (3), then remove pin (4). a
* Pull out pin using bar.
4. Sling the swing bracket, then pull out swing cyl-
inder head pin (5).
5. Move swing bracket (6) to opposite of swing cyl-
inder head, then disconnect and remove it.
* There are shims installed, check the number,
thickness and insalled position. CWPO6584

r+ kg Swing bracket assembly : 60 kg

^

INSTALLATION OF SWING
BRACKET ASSEMBLY
PC27MRX, PC30MRX

l Carry out installation in the reverse order to re-

moval.

u
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.

& Bushing inside surface :

Anti-friction compound (G2-T)

* Adjust the shim thickness so that the clear-

ance (a + blbetween swing cylinder head and
arm mounting portion is below 1 mm.

CWPOfi46fi

PC27 - 45MRX-1 30- 173

0
DISASSEMBLY AND ASSEMBLY SWING BRACKET

REMOVAL OF SWING BRACKET

ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

1. Remove work equipment assembly. For details,

see REMOVAL OF WORK EQUIPMENT ASSEM-
BLY

2. Disconnect 2 hoses (2) from boom cylinder as-

sembly.
* After disconnection fit a blind plug.

3. Sling the boom cylinder assembly and remove

bottom pin (2), then lift off boom cylinder assem-
bly. m
* There are shims installed, check the number,
thickness and insalled position.

& kg boom cylinder assembly :

45 kg (PC35MRX)
50 kg (PC40MRX. PC45MRX)

4. Set the block under the swing cylinder, then re-

move head pin (4). a
t There are shims installed, check the number,
thickness and insalled position.

g Start engine, then retract swing cylinder.

5. Sling swing bracket assembly, then remove pin

(5) using eye bolt 0.

& kg pin : 30 kg

6. Lift off swing bracket assembly (6). m

* If there are shims installed, check the num-

ber and thickness and installed position.

&I kg Swing bracket assembly : 85 kg

30-174 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY SWING BRACKET

INSTALLATION OF SWING
BRACKET ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

HP07346
Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance a between boom cylinder (3) bottom and
swing bracket (6).
l Clearance a : Below 1 mm
l Standard shim thickness : 1 mm

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.
CUP07347
& Pin sliding surface, when assembling :
Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

* Adjust the shim thickness so that the clear-

ance b between swing cylinder (7) head and
swing bracket (6).
l Clearance b : Below 1 mm
l Standard shim thickness : 1 mm

C
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.
CWPO7348
& Pin sliding surface, when assembling :
Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

Ir Adjust the shim thickness so that the clear-

ance c between swing bracket (6) and revolv-
ing frame (8).
l Shim thickness : 0.5, 1.0 mm

l Bleeding air
Bleed the air from bucket cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air.

PC27 - 45MRX-1 30-175

a
DISASSEMBLY AND ASSEMBLY BLADE

REMOVAL OF BLADE ASSEMBLY

PC27MRX, PC30MRX

A Stop the machine on a flat ground and lower

the work equipment and the blade completely
to the ground.
a Disconnect the negative (-1 terminal of the bat-
tery.

1. Remove the blade cylinder guard (1).

2. Pull out the pin (2) on the blade cylinder bottom

side. a
* There are shims installed, check the number,
thickness and insalled position.

3. Connect the battery, start the engine, retract the

piston completely, lift the blade cylinder assem-
bly (3) and hang it from the machine.

4. Set the block @ to the blade arm and pull out the
pins (4) and (5).
* Make the clearance between the blade arm
and the block zero.

5. Start the engine, move the machine backward and

remove the blade assembly (6). t------i CWPO6510

I+lkg Blade assembly: 130 kg (PC27MRX)

150 kg (PC30MRX)

INSTALLATION OF BLADE
ASSEMBLY
PC27MRX, PCSOMRX

l When installing the blade assembly, reverse the

removing procedures.

& Bushing inside surface at inserting pin :

Anti-friction composition (G2-T)

A When aligning pin holes, never put your fin-

ger in any pin hole.

t Insert shims certainly.

30- 176 PC27 - LLSMRX-1

a
DISASSEMBLY AND ASSEMBLY BLADE

INSTALLATION OF BLADE
ASSEMBLY
PC35MRX, PC4OMRX, PC45MRX

l Carry out installation in the reverse order to re-

moval.

When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling :

Molybdenum disulphide grease (LM-PI CWPO7353

,Q_ Lubricate after assemble : Grease

(Hyper white grease or equivalent)

Sr Adjust the shim thickness so that the clear-

ance a between boom cylinder (6) bottom and
blade (4).
lClearance a : Below 1 mm
lStandard shim thickness : 1 mm

a When aligning the position of the pin hole,

never insert your fingers in the pin hole.

& Pin sliding surface, when assembling : CWPO7354

Molybdenum disulphide grease (LM-PI

& Lubricate after assemble : Grease

(Hyper white grease or equivalent)

+ Adjust the shim thickness so that the clear-

ance b between blade and track frame.
l Standard shim thickness : 1 mm

30-178 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY SEAT BRACKET, R.H. AND L.H. PPC VALBE

REMOVAL OF SEAT BRACKET,

R.H. AND L.H. PPC VALBE
ASSEMBLY
PC27MRX, PC30MRX

g Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Disconnect the cable from the negative (-1 ter-
minal of the battery.

1. Remove floor mat (I).

2. Remove handrail (2).

3. Remove engine hood (3) and side cover (4).

+ Remove canopy before.

&I kg Canopy assembly : 25 kg

4. Remove hydraulic tank hood (5).

5. Remove side cover (61, (7).

6. Remove travel speed selector switch (8).

* Disconnect connector (S3).

7. Remove floor (9).

8. Remove side cover (IO).

L DXP01004

9. Remove side cover (II).

\ CWPO6590

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY SEAT BRACKET, R.H. AND L.H. PPC VALBE

10. Disconnect blade control cable (12) and (13) from

lever.
-k Make sure the mounting dimension, then dis-
connect it.

11. Disconnect engine control cable (14). m

12. Disconnect R.H. PPC valve wiring connectors (151,

(16), (17) and (18).
* Put a mark.

CUP06591 CWPO6592

13. Disconnect L.H. PPCvalve wiring connectors (19),

(201, (211, (22) and (23).
Ir Put a mark.

14. Disconnect main control valve piping, for discon-

necting the piping of solenoid valve.
1) Disconnect hose (24) from swing motor.
2) Disconnect hose (25) from main pump.
3) Disconnect 2 hoses (26) from R.H. travel and
2 hoses (27) from L.H. travel.
* Hoses between control valve to swivel
joint.
4) Disconnect 2 boom control hoses (28).
* Hoses between control valve to boom cyl-
inder.

15. Disconnect hoses (29) and (30) to R.H. and L.H.

PPC valve.
+- Hoses between R.H. and L.H. PPCvalve to PPC
lock solenoid valve.

16. Disconnect R.H. and L.H. PPC valve drain hoses

(31) and (32).
+ Hoses between R.H. and L.H. PPC valve to so-
lenoid.

30-180 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY SEAT BRACKET,R.H. AND L.H. PPC VALBE

17. Disconnect 4 upper PPC hoses (33).

* Put a mark:

18. Disconnect 4 lower PPC hoses (34).

-k Put a mark.

19. Remove mounting bolt, then remove seat, R.H.

and L.H. PPC valve assembly (35).
* Sling up slowly, if not disconnected portion.

& kg Seat, R.H. and L.H. PPC valve assembly

: IlOkg

CWP06597
INSTALLATION OF SEAT
BRACKET, R.H. AND L.H. PPC
VALBE ASSEMBLY
PC27MRX, PCSOMRX

l Carry out installation in the reverse order to re-

moval.

M
A Adjust fuel control lever and measure the en-
gine speed. For details, see TESTING AND
ADJUSTING, Adjusting of fuel control lever.

l Refilling with oil (hydraulic tank)

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.

l Bleeding air
Bleed the air from R.H. & L.H. PPC valve assem-
bly, R.H. & L.H. travel motor and boom cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air.

PC27 - 45MRX-1 30-l 81

0
DISASSEMBLY AND ASSEMBLY SEAT BRACKET

REMOVAL OF SEAT BRACKET

ASSEMBLY
PC35MRX

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
g Disconnect the cable from the negative (-1 ter-
minal of the battery.
1. Remove operator’s cab assembly. For details, see
REMOVAL OF OPERATOR’S CAB ASSEMBLY.
(For operator cab specification machine only)
2. Remove canopy assembly. For details, see RE-
MOVAL OF CANOPY ASSEMBLY.
(For canopy specification machine only)
3. Remove left upper cover (I) and left cover (2).
4. Remove 2 floor plates (3).
5. Remove handrail (4) and (5).
6. Remove cover (6).
7. Remove fuse box cover assembly (7).
Ir Move it down side.
8. Remove cover (8)
9. Remove right lever stand assembly (9) with
bracket.
* Move it down side.
10. Remove left lever stand assembly (IO).
-k Disconnect 4 harness clamps.
Ir Move it down side.
11. Lift off seat bracket assembly (11) using eye bolt
0.
* Disconnect block (12), PPC hose clamp and
harness clamp from under of seat bracket,
while lifting operatioin.

el
kg Seat bracket : 70 kg

INSTALLATION OF SEAT
BRACKET ASSEMBLY
PC35MRX
l Carry out installation in the reverse order to re-
moval.

30-182 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE

REMOVAL OF SOLENOID
VALBE ASSEMBLY
PC27MRX, PC30MRX

Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
Release the remaining pressure in the hydraulic
circuit. For details, see TESTING AND AD-
JUSTING, Releasing remaining pressure in hy-
draulic circuit.
Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove hydraulic oil.

- : Hydraulic oil : 28.5 e

2. Remove hand rail (I).

3. Remove floor mat, then remove travel speed se-

lector switch (2) from floor.
* Disconnect the wiring connector (S3) fortravel
selector switch.

4. Remove floor plate (3).

5. Disconnect control valve piping (4) (to motor) and

(5) (from main pump).

6. Disconnect control valve piping (6) (to R.H. travel

motor), (7) (to L.H. travel motor) and (8) (boom
cylinder).

7. Disconnect solenoid valve wiring connector (9)

(VI) and (IO) (V2).

8. Disconnect drain hose (11) (right) and (12) (left).

9. Disconnect hose (13) (travel speed selector) to

swivel joint.

10. Disconnect hose (14) to left PPC valve.

11. Disconnect drain hose (15) to hydraulic tank.

12. Disconnect hose (16) to right PPC valve.

13. Disconnect hose (17) from control valve.

14. Remove mounting bolt, then remove solenoid

valve assembly (18).

PC27 - 45MRX-1 30-183

0
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE

INSTALLATION OF SOLENOID
VALBE ASSEMBLY
PC27MRX. PCSOMRX

l Carry out installation in the reverse order to re-

moval.

l Refilling with oil (hydraulic tank)

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.

l Bleeding air
Bleed the air from hydraulic circuit. For details,
see TESTING AND ADJUSTING, Bleeding air.

30-184 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE

REMOVAL OF SOLENOID
VALBE ASSEMBLY
PC35MRX ’

A Stop the machine on the horizontal ground, then

lower the work equipment completely to the
ground and stop the engine.
A Release the remaining pressure in the hydraulic
circuit. For details, see TESTING AND ADJUST-
ING, Releasing remaining pressure in hydraulic
circuit.
a Disconnect the cable from the negative (-) ter-
minal of the battery.

1. Remove left lower cover and upper cover of main

control valve.

2. Disconnect hose (I) from main control valve.

* It’s impossible to remove solenoid assembly,
if not disconnect the hose.
* After disconnection fit a blind plug.

3. Remove mounting bolt from block (2).

4. Disconnect wiring connector (3) (VI) and (4) (V2).

5. Disconnect 4 hoses (5) from solenoid valve as-

sembly.
* After disconnection fit a blind plug.
* After disconnecting the hoses, fit tags to dis-
tinguish them.

6. Remove solenoid valve assembly (6).

INSTALLATION OF SOLENOID
VALBE ASSEMBLY
PC35MRX

l Carry out installation in the reverse order to re-

moval.

l Refilling with oil (hydraulic tank)

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.

m Filler plug (PC35MRX) :

181.3 - 240.1 Nm 118.5 - 24.5 kgm}

PC27 - 45MRX-1 30- 185

0
DISASSEMBLY AND ASSEMBLY FLOOR FRAME

9. Disconnect hose (5), (6) and (7) from breaker PPC

valve assembly.
Sr Breaker specification machine only

10. Disconnect heater hose (8) and (9) at engine side.

or Canopy specification machine only

11. Disconnect fuel control cable (IO) at fuel injection

pump side. a
Ir Make sure the mounting dimension before
disconnection.

12. Disconnect wiring connector (11) (M42).

PC27 - 45MRX- 1 30-189

0
DISASSEMBLY AND ASSEMBLY FLOOR FRAME

13. Disconnectwiring connector (12) (M54), (13) (M56)

and (14) (M55).

14. Disconnect PPC circuit return hose (15), then re-

move bracket (I 6).

15. Disconnect 2 swing control cable (17). m

* Make sure the mounting dimension before
disconnection.

16. Disconnect 2 blade control cable (18). m

* Make sure the mounting dimension before
disconnection.

30-190 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY CANOPY

REMOVAL OF CANOPY
ASSEMBLY
1. Remove mounting bolt. m

2. Lift off canopy assembly (1).

,E?I kg Canopy assembly :

25 kg (PC27MRX, PC30MRX)
35 kg (PC35MRX. PC40MRX. PC45MRX)

INSTALLATION OF CANOPY
ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

m Canopy assembly mounting bolt :

98 - 123 Nm {IO - 12.5 kgm}

30-192 PC27 - 45MRX- 1

Cc
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB

REMOVAL OF OPERATOR’S
CAB ASSEMBLY
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Remove operator’s seat (1).

2. Remove left lever stand lower cover (2).

3. Remove speaker assembly (3).

fl Disconnect wiring connector (B5) and (B6)
from rear of speaker.

4. Remove fuse box assembly (4).

PC27 – 45MRX-1 30-193

3
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB

5. Remove 4 mounting bolts (5) for lever stand as-

sembly, then move to front side it.
fl Move lever stand assembly to front side.
fl It could not lift up, if not move lever stand to
front side.

6. Lift off operator’s cab assembly (6).

0 Operator’s cab assembly : 210 kg

INSTALLATION OF
OPERATOR’S CAB ASSEMBLY
• Carry out installation in the reverse order to re-
moval.

30-194 PC27 – 45MRX-1

3
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

REMOVAL OF COUNTERWEIGHT
ASSEMBLY
g Stop the machine on the horizontal ground, then
lower the work equipment completely to the
ground and stop the engine.
a Disconnect the cable from the negative (-1 ter-
minal of the battery.

Remove engine hood (I).

Remove left upper cover (21, left cover (31, right

cover (4) and right lower cover (5).

Lift off counterweight assembly (6). a

* Using a lever block or bar, adjust the balance
of counterweight assembly, and lift off.

&I k9 Counterweight assembly :

340 kg (PC27MRX)
400 kg (PC30MRX)
700 kg (PC35MRX)
550 kg (PC40MRX)
750 kg (PC45MRX)

INSTALLATION OF
COUNTERWEIGHT ASSEMBLY
l Carry out installation in the reverse order to re-
moval.

& Thread of counterweight mounting bolt :

Thread tightener (LT-2)

w Counterweight mounting bolt :

490 - 608 Nm t50 - 60 kgm} (PC35MRX)

m Counterweight mounting bolt :

623 - 1,029.7 Nm (84 - 105 kgm}
(PC40MRX. PC45MRX)

PC27 - 45MRX- 1 30-195

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

DISASSEMBLY OF HYDRAULIC
BREAKER ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

1. Setting of breaker
Using eye bolt a, sling hydraulic breaker assem-
bly (I) and set it on work stand with its side (charg-
ing valve side) up.

a If the charging valve is broken, high-pres-

sure gas may spout out. Accordingly, when
moving or installing the breaker, take care
extremely not to break the charging valve. CLPOl334

2. Charging valve
1) Loosen charging valve (2) to discharge all gas
(N2) from back head.

a
Since the back head is filled with high-
pressure gas (N2), do not loosen the
charging valve more than 1 turn.

CLPO1335

2) Push tip of check adapter (an attached tool)

GJ, in which pressure gauge (an attached tool)
@ is screwed, into charging valve (2) and
check that all gas (N2) has been discharged.

3) Remove charging valve (2).

Sr Check the O-ring fitted to the charging
valve. If it is deteriorated, scratched, or
deformed, replace it with new one.

CLPO1335

30- 196 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

3. Back head
I) Set a wood block (about 15 mm thick) under
hydraulic breaker assembly (1) and secure
them with C-clamp 0, with pipe clamp of back
head up.

CLPOl337

2) Remove nuts (3) and washers.

CLPO1338

3) Remove back head (4).

* Pull out the back head, taking care not to
scratch the back head with the through
bolts.

4. Cylinder unit
1) Loosen through bolts (5).
2) Remove C-clamp 0.

CLPOI 340

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

3) Sling cylinder unit (6) and remove through

bolts (5).

4) Remove cylinder unit (6).

* When removing the cylinder unit, take
care not to scratch it.

5) Disassemble cvlinder unit further as follow. I

i) Remove Oiring (7) from cylinder unit.

/ CLPOl343

ii) Hit impact side (front head side) of piston

(8) with plastic hammer, etc. to remove
piston (8) together with seal retainer from
back head.
Ir Do not scratch the piston.
Do not pull out the piston forcibly, but
pull it out slowly, aligning it with the
cylinder.

CLPO1344

30-198 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

iii) Remove seal retainer (9) from piston, tak-

ing care that it will not touch piston un-
evenly.

CLPO1345

iv) Remove valve (IO) from cylinder.

t Take care that the seal retainer will not
touch unevenly.
Sr Take care, since the valve may be re-
moved together with piston (8).

v) Remove dust seal (I 1) and U-packing (12)

from cylinder.
Ir If the dust seal and U-packing cannot
be removed easily, use a flat-head
screwdriver 0, the tip of which is bent
about 10 mm to 60 degrees.

CLPOl348 CLPO13

vi) Remove plug (13) from cylinder.

* Check the O-ring fitted to the plug. If
it is deteriorated, scratched, or de-
formed, replace it with new one.

CLPO1350

PC27 - 45MRX- 1 30-199

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

vii) Remove 3 U-packings (14) from inside

wall of seal retainer.
Ir If the U-packings cannot be removed
easily, use a flat-head screwdriver 0,
the tip of which is bent about 10 mm
to 60 degrees.
viii) Remove O-ring (15) from outside wall of
seal retainer.

CLPO1351 CLP01352

ix) Clean removed piston (8), seal retainer (9),

valve (IO), and cylinder (16) in diesel fuel
or incombustible oil.
+ Check the sliding surfaces (inside and
outside walls) of each part for flaws
by feeling them with the fingers.
If there is a flaw on which a nail is
hitched, repair it by polishing with
sandpaper of #800 - #I200 in the cir-
cumferential direction. Do not polish
in the axial direction.
* After repairing any flaw, clean the slid-
ing surfaces carefully.

5. Front head
Disassemble front head further according to fol-
lowing procedure.
1) Set front head (17) on work stand with dummy
chisel mounting part down.
2) Remove pin (18).
t If the ring of the pin cannot be raised, use a
screwdriver or another pointed tool.
3) Remove rod pin (19).

CLPOl354

CLP0135E

30-200 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

4) Remove grease fittings (20).

Ir Clean the grease fittings in diesel fuel or 2
cleaning oil.

CLPO1357

5) Setfront head (17) on workstand with dummy

chisel mounting part up.

CLPO1358

6) Remove dummy chisel (21).

CLPO1359

7) Drive spring pin (22) and stopper pin (23) out

of dummy chisel mounting part with pin
(about 9 mm in diameter) @I.

CLPO136C CLPO136'

PC27 - 45MRX-1 30-201

Co
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

8) Remove snap ring (24) with snap ring pliers

0.

30-202 PC27 - 45MRX-1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

ASSEMBLY OF HYDRAULIC
BREAKER ASSEMBLY
PC35MRX, PC40MRX, PC45MRX

* Before starting the assembly work, prepare the

seal kit.
1. Front head
Assemble front head as follow.
1) Set front head on work stand with dummy
chisel mounting part up.
2) Remove snap ring (24) with snap ring pliers
0.
CLPOl363

3) Insert spring pin (22) from dummy chisel

mounting part side, then drive in stopper pin
(23) by hitting it lightly with a hammer, etc.
* Take care not to drive out the spring with
the stopper pin.

CLPO1361 CLPO1364

4) Install dummy chisel (21).

CLPO1359

5) Set front head on work stand with dummy

chisel mounting part down.
6) Install rod pin (19).

CLPO135!

PC27 - 45MRX- 1 30-203

a
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

7) Install ring pin (18) to rod pin, then turn over

ring inward.
li When turning over the ring, take care not
to catch your hand in it, since the spring
returns it back.

CLPOl365

8) Install grease fitting (20).

CLPO1357

2. Cylinder unit
I) Assemble cylinder unit according to follow-
ing procedure.
i) Fit U-packing (12) and dust seal (I I) to the
seal groove from the deeper side of the
front of the cylinder.

CLPO1348 CLP01366

Ir When fitting a seal to the seal groove,

take care not to bend it sharply but
make U-form of a part of itself with
the forefinger. Fit the bottom of the
seal in the seal groove, then push the
other parts in the seal groove upward
and push in the U-formed part at last.

CLPOl367

30-204 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

Ir Check “fitness” and “direction of the

lips” of U-packing (12) and dust seal
(11) again, then apply clean hydraulic
oil to the deep part of cylinder (16).

ii) Coat hydraulic oil to O-ring and install

plug (13) to cylinder.

CLPOl350

iii) Coat hydraulic oil to valve (IO) sufficiently,

then insert it in cylinder.
* Se sure to insert the valve with the
hand. Never drive it in with a ham-
mer, etc.
1: After inserting the cylinder, check that
the valve can be moved lightly with
the hand.

iv) Install 3 U-packings (14) to the inside wall

of seal retainer.
Ir Set the lips in the directions shown in
the figure at right.

CLPOl369 CLPOl371

PC27 - 45MRX- 1 30-205

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

* When fitting a seal to the seal groove,

take care not to bend it sharply but
make U-form of a part of itself with
the forefinger. Fit the bottom of the
seal in the seal groove, then push the
other parts in the seal groove upward
and push in the U-formed part at last.

CLP01367

VI Fit O-ring (15) to outside of seal retainer.

CLPO1371 CLPO1372

vi) Clean piston (8) in diesel fuel or cleaning

oil and dry it with compressed air, then 0
apply clean hydraulic oil all over piston.
vii) Apply hydraulic oil to inside and outside
of seal retainer (9) sufficiently, then install
it to piston.

\ -
%

------7 CLPO1371 CLPO1345

viii) Insert piston (8) and seal retainer together

in cylinder from back head side, then drive
them in by lightly hitting them with a plas-
tic hammer, etc. until piston (8) stops.
* Align the piston with the cylinder and
hit it lightly to insert it.
Ir If the piston is inserted to the end, the
seal retainer is sunken about 6 mm
from the end of the cylinder.

30-206 PC27 - 45MRX- 1

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

ix) Fit O-ring (7) to cylinder unit,

/ CLPOl343

2) Check and clean through bolts (5) and nuts

(3) according to following procedure.
i) Clean through bolts and nuts in diesel fuel
or cleaning oil, then check them for wear,
damage, and deformation.
ii) Check threaded parts of through bolts
with color checker for cracking.

3) Sling cylinder unit (6) and install it to head.

* Take care not to scratch the cylinder with
the front head.

4) Align cylinder unit with front head and tighten

through bolts (5) lightly.

& Threads of through bolt : Lubricant

* After coating lubricant to the threads, take

care that dirt and dust will not stick to
them.

PC27 - 45MRX- 1 30-207

Cc
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

5) Secure cylinder unit to work stand with C-

clamp GiJ.
6) Tighten through bolts (5).

‘A - Ill CLPOl377

Ir Tighten the 4 through bolts evenly so that their

. tips will not project into side bolt mounting
holes a.

CLPO1378

3. Back head
I) Insert back head (4) and drive it in by hitting it l=m--I \ \
with plastic hammer, etc. lightly.

2) Set washers and tighten nuts (3).

CLPO1338

30-208 PC27 - 45MRX- 1

a
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

* Tighten the nuts in the diagonal order as

shown in the figure at right.

w Nut: 35 kgm

CLPO1380

4. Greasing
Supply grease through grease fittings (20).

CLPO1357

5. Charging valve
I) Set breaker on work stand with its side (charg-
ing valve mounting side) up.
2) Apply hydraulic oil to O-ring and install charg-
ing valve (2).
* If the charging valve is loosened, gas will
leak. Accordingly, tighten it securely.

CLPO1335

6. Charging with gas (Nz) I

1) Charge back head with gas (Nz). For details,
see TESTING AND ADJUSTING, Testing gas
(Nz) pressure in hydraulic breaker and charg-
ing it with gas.

PC27 - 45MRX- 1
DISASSEMBLY AND ASSEMBLY HYDRAULIC BREAKER

After charging with gas (Nz), apply soap wa-

ter to following parts to check for gas leak-
age.
i) Mounting part of charging valve (2).

CLPOl382 I

ii) Joint of cylinder unit (6) and back head

(4).

CLPO1383

30-210 PC27 - 45MRX-1

0
MAINTENANCE STANDARD SWING MACHINERY

SWING MACHINERY
PC27MRX, PC30MRX, PC35MRX-1

4-

12.3Nm
1.25kom)

9JA00741

40-2 PC27 - &MRX- 1

0
MAINTENANCE STANDARD SWING MACHINERY

Unit: mm

Criteria

Backlash between swing

motor shaft and No.1 sun

0.09 - 0.25

n gear and No.2 plan-

f swing pinion col-

ace contacting with

PC27 - 45MRX-1 40-3

0
MAINTENANCE STANDARD SWING MACHINERY

PWOMRX, PC45MRX-1

O.O* 12.3Nm
.25+ 1.25knl

9JA00742

40-4 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD SWING MACHINERY

Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit

Backlash between swing
1 motor shaft and No.1 sun
0.04 - 0.11 -
gear

Backlash between No.1

2 sun gear and No.1 plan- 0.12 - 0.28 0.6
etary gear
Backlash between No.1
3 g!aytary gear and rrng 0.14 - 0.38 0.6

Backlash between No.1

4 @a$;:;? gear and No.2 0.10 - 0.26 -
Replace
Backlash between No.2
5 sun gear and No.2 plan- 0.12 - 0.28 0.6
etary gear
Backlash between No.2
6 ;Faytary gear and rrng 0.14 - 0.38 0.6

Backlash between No.2

7 ;[;yrFry gear and swmg 0.07 - 0.21

8 Backlash between swing

prnron and swing crrcle 0.14-0.73 2.0
I
Standard size Tolerance Repair limit Apply hard-
Wear of swing pinion col- chromium
9 lar surface contacting with plating recon-
oil seal 52 - dition. or
- i.074 replace

PC27 - 45MRX- 1 40-5

0
MAINTENANCE STANDARD SWING CIRCLE

SWING CIRCLE
The diagram shows the PC40MRX, PC45MRX.

A-A 9Jh00766

Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit

1 Axial clearance of bearing Replace

0.03 - 0.13 0.23

40-6 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD TRACK FRAME

TRACK FRAME
PC27MRX, PC30MRX-1
RUBBER SHOE SPECIFICATION

SWPO5270

40-8 PC27 - 45MRX- 1

a
MAINTENANCE STANDARD TRACK FRAME

Unit: mm

No Check item Criteria Remedy

Standard clearance Clearance limit

Rebuild
Track
frame 108 112
Vertical width
1
of idler guide
Idler Rebuild or
support 106 102
replace

Track
frame 161 165 Rebuild
Horizontal
2 width of idler
guide Idler Rebuild or
support 159 155
replace
-
Standard size Repair limit
I I I I
Free length Irlstalled lengtl

I
Recoil Rubber shoe Replace
3 spring specification 246 188.4

Steel shoe
specification 246 206.4
1 t:

PC27 - 45MRX- 1 40-9

0
MAINTENANCE STANDARD TRACK FRAME

PC35MRX, PC40MRX, PC45MRX-1

STEEL SHOE SPECIFICATION

PC40,45MR: 117.0*19.6Nm
(18.0~2.0kom1

/
3
(18.0~2.Obm)

9JA00767

40-10 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD TRACK FRAME

Unit: mm
I I
No
-
Check item
I
Criteria
I
I
Remedy

Standard clearance Clearance limit

I
Track Rebuild
96 100
Vertical width frame
1
of idler guide
Idler Rebuild or
support I replace

Track
Horizontal frame
2 width of idler
guide Idler Rebuild OI
159 155
support replace
I

Standard size Repair limit

Free length Installed length Installed load Free length Installed load
Recoil spring
30.9 kN 28.5 kN
rubber shoe PC35MRX 257 188 250.6
(3.153 kg} 12,901 kg}
specification

PC40MRX 42.4 kN 39.0 kN Replace

3 PC45MRX 302 202.2 294.5
(4,326 kg} I3,980 kg1

kN 17.6 kN
PC35MRX 257 213 19.7 250.6
Recoil spring (2,012 kg} Il.791 kg1
steel shoe
specification I%% 27.0 kN 24.0 kN
302 238.2 294.5
12,748 kg} {2,446 kg1

PC27 - 45MRX- 1 40-11

0
MAINTENANCE STANDARD IDLER

IDLER
PC27MRX, PCSOMRX-1
RUBBER SHOE SPECIFICATION

Unit: mm
-
No Check item Criteria Remedy

Standard clearance Clearance limit

Outside diameter of
protrusion 344 -

Outside diameter of tread 306 -

Rebuild or
Width of protrusion 28 20 replace

4 Total width 64 59
-

5 Width of tread 18 22
-
Tolerance Standard Clearance
Standard
size Shaft Hole clearance limit
Clearance between idler Replace
6
shaft and idler support
+0.06
35 O-0.085 -
J.025 0

40-12 f’C27 - 45MRX- 1

a
MAINTENANCE STANDARD IDLER

PC35MRX, PC40MRX, PC45MRX-1

RUBBER SHOE SPECIFICATION

9JA00799

40-14 PC27 - 45MRX-1

a
MAINTENANCE STANDARD IDLER

Unit: mm

No. Check item Criteria Remedy

I Standard clearance 1 Clearance limit

Outside PC35MRX 338 330

1 diameter of
protrusion
PC40MRX
PC45MRX 377 369

PC35MRX 300
Outside
2 diameter of
tread PC40MRX
PC45MRX 335 327

Rebuild or
PC35MRX replace
28 20
Width of I
3
protrusion
PC40MRX
PC45MRX 39 31

Total width
PC40MRX
PC45MRX 75 70

Width of tread 18 22

Clearance between idler

shaft and idler support

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
‘-‘erference
II IL between idler
7
an d bushing
+0.079 + 0.039 0.015 -
42
+0.054 0 0.079 -

Standard clearance Clearance limit

8 Side clearance of idler

0.25 1.0

I Standard size I Reoair limit

Thickness of PC35MRX 8.7 4.7 Rebuild or

9 the idler tread
replace
(center of tread)
PC40MRX
10.3 6.3
PC45MRX
-

PC27 - 45MRX-1 40-15

0
MAINTENANCE STANDARD CARRIER ROLLER

CARRIER ROLLER
PC27MRX, PC30MRX-1

SDPD3266

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

pd;;;fde diameter of Replace
1
70 62

40-16 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD CARRIER ROLLER

PC35MRX, PC4OMRX, PC45MRX-1

The diagram shows the PC40MRX and PC45MRX.

9JA00789

Unit: mm

Criteria Remedy

Outside diameter of

Clearance between shaft

Thickness of the idler tread

PC27 - 45MRX- 1
MAINTENANCE STANDARD TRACK ROLLER

TRACK ROLLER
RUBBBER SHOE SPECIFICATION
The diagram shows the PC40MRX and PC45MRX.

9JA00790

40-18 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD TRACK ROLLER

Unit: mm

No Check item Criteria Remedy

Standard size Repair limit

‘C27MRX
Outside ‘CSOMRX 108 102
1 diameter of PC35MRX
protrusion
PC40MRX 117
123
PC45MRX
-
PC27MRX
85 77
Outside EKE
2 $rayter of Rebuild or
PC4OMRX 95 87 replace
PC45MRX

PC27MRX
PCBOMRX 26 20

Outside
3 diameter of PC35MRX 30.3 24.3
flange

PC40MRX
PC45MRX 41 35

%3EE
PC35MRX
94 -
-
I-
4 Total width
PC40MRX
PC45MRX 110 -

PC27MRX
PCSOMRX 34 37

Rebuild or
5 Width of tread replace

Clearance
0.144 -
6 betweenshaft 1.5
0.196 I
and bearing

-0.025 +0.142
;:;;I!; 35
- 0.050 + 0.080

Standard _ Tolerance
size Shaft 1 Hole
Replace

Clearance limit I

8 ~;~o$arance
E;Kis
PC35MRX
0.20 0.74

PC40MRX 0.81
0.25
PC45MRX

Standard size Repair limit

Thickness of the tread Rebuild or
(center of tread) replace
26.5 22.5

PC27 - 45MRX- 1 40-19

0
MAINTENANCE STANDARD SPROCKET

SPROCKET
PC35MRX, POIOMRX, PC45MRX-1
The diagram shows the PC45MRX.

SKP02914

40-20 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD SPROCKET

Unit: mm

No. Check item

I
1 Standard size T
Criteria

Tolerance Repair limit

TRemedy

Wear in +I.0
diameter of PC35MRX 344.3 -2.0 332
1 sprocket tooth
root +I.0
PC40MRX
380.37 -2.0 368
PC45MRX

Wear in PC35MRX 386.2 +1.5 374

diameter of
2 sprocket tooth
PC40MRX
top 423.99 412
PC45MRX -!.o

PC35MRX 20 18 Rebuild or
Wear in width replace
3 of sprocket
tooth top - 24

+0.5 24
Wear in width -1.0
4 of sprocket
tooth root PC40MRX +0.5
33 30
PC45MRX -1.0

+0.492
PC35MRX 67.15 61.0
Thickness of - 1.075
5 sprocket tooth
root PC40MRX +0.492
75.185 69.0
PC45MRX - 1.075

PC27 - 45MRX- 1 40-21

0
MAINTENANCE STANDARD TRACK SHOE

TRACK SHOE
RUBBER SHOE SPECIFICATION

.___________________-____

A-A SWPOGI39

40-22 PC27 - 45MRX- 1

a
MAINTENANCE STANDARD TRACK SHOE

Unit: mm

No, Check item Criteria Remedy

I
Standard size Repair limit

1 JVear of lug height

25 5

I
PC27MRX 34 42

PC30MRX 32 40
Wear of roller
2 guide portion
PC35MRX 31 40
Replace

38
I

Standard size Tolerance Repair limit

PC27MRX 24 - 28
Wear of
3 contactin
portion 0 3 21 f0.5 25
sprocket Eo5Kz

PC27 - 45MRX- 1 40-23

0
MAINTENANCE STANDARD TRACK SHOE

DOUBLE-GROUSER SHOE, CITY-PAD SHOE (OPTION)

PC27MRX, MPC30MRX, PC35MRX-1

\
12 c I
9JA00792

40-24 PC27 - 45MRX- 1

a
MAINTENANCE STANDARD TRACK SHOE

Unit: mm

No. Check item Criteria Remedy

Standard size Reverse limit Repair limit

1 _ink pitch
Replace
bushing and
- pin

2 Bushing outside diameter 32 26

- I I I
I Standard size Repair limit
Lug welding,
3 Height of grouser rebuild or
16.5 replace
-
Rebuild or
4 Link height 61
replace
-
Tolerance
Standard Standard Interfer-
size Shaft Hole interference ence limit
Interference between
5 bushing and link I
32 +0.15 +0.05 0.07 -
I +0.12 I 0 0.15 -
- I I I I

Interference between regular

6 pin and link
-

Replace
Clearance between master
7
pin and link

-
Clearance between regular Shaft 19 +0.05 0.15 -
8 pin and bushing Hole 19.5 +0.12 +0.2 0.58 -
-
Clearance between master Shaft 18.93 +0.05 0.32 -
9 pin and bushing Hole 19.5 0 +0.2 0.77 -

Standard ciearance Standard cl.earance Clearance limit

b;_y-J;) / 1;;;;;; (one side)
Clearance between link
IO contact portion
- Adjust

11 Protrusion of regular pin 1.5

- I
Standard size Repair limit
Lug welding,
12 Thickness of grouser rebuild or
22.5 replace
-
Thickness of link
Rebuilt or
13 (press fitting portion of 15.5 9.5
replace
bushing)
-
Reverse or
14 Thickness of bushing 6.25 3.25
replace
II I
- I

PC27 - 45MRX- 1 40-25

0
MAINTENANCE STANDARD TRACK SHOE

ROAD LINER
PC27MRX, PC30MRX. PC35MRX-1

14

I
9JA00793

40-26 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD TRACK SHOE

Unit: mm

Check item Criteria Remedy

I I

I-
Standard size Reverse limit Repair limit

I Link pitch
102 - 107 Replace
bushing and
pin

2 Bushing outside diameter 32 - 26

I
Standard size I Repair limit

3 Height of grouserr (pad) replace

44 20

Rebuild or
4 Link height 61 55
replace

Tolerance
Standard Standard I nterfer-
size Shaft Hole interference ence limit
Interference between
5 bushing and link
32 +0.15 +0.05 0.07 -
+0.12 0 0.15 -

6
Interference between
pin and link
regular 19 / ;“,:$ / +y / o-07-o*15 1 - (
Tolerance
Standard Standard Clearance Replace
size Shaft Hole clearance limit
Clearance between master
7
pin and link Shaft 18.93 +0.05 +0.05 0.02 -
Hole 19 0 0 0.12 -

Clearance between regular Shaft 19 +0.05 0.15 -

8 kO.2
pin and bushing Hole 19.5 +0.12 0.58 -

Clearance between master Shaft 18.93 +0.05 0.32 -

9 f0.2
pin and bushing Hole 19.5 0 0.77 -
-
Standard clearance Standard clearance Clearance limit
(one side) (eath side) (one side)
Clearance between link
10 contact portion
0.2 - 0.9 0.4- 1.8 - Adjust
I I I I

11 Protrusion of regular pin 1.5

Standard size Repair limit

Thickness of link
Rebuilt or
12 (press fitting portion of
15.5 9.5 replace
bushing)

13 Thickness of bushing
I
6.25 3.25
I Reverse or
replace

Tightening torque of shoe 134.84 + 7.35Nm 113.75 + 0.75kgm) Retighten

14
bolt I I

PC27 - 45MRX- 1 40-27

0
MAINTENANCE STANDARD TRACK SHOE

TRIPLE GROUSER SHOE, CITY-PAD SHOE, ROAD LINER

PC40MRX, PC45MRX-1

6 II
\

9JA00794

% 1. Triple grouser shoe, city-pad shoe (PC4OMRX)

% 2. Triple grouser shoe (PC45MRX)
% 3. Road liner (PC40MRX, PC45MRX)

40-28 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD TRACK SHOE

Unit: mm
-
No. Check item Criteria Remedy
-
Standard size Reverse limit Repair limit T he pin and bush-
_ ir ig are able to use
Link pitch if i reverse until
135 138 143 ?ach to reverse
Ii’mit. If these had
- -e xceeded the re-
air limit, replace
2 Bushing outside diameter 35 32 29 inl bushing or
i nk assemblv

-L ug welding,
r#ebuild or
Height of grouser r eplace

Fleolace

Flebuild OI
4
r eplace
-

Interference between bush-

5 ing and link

ieplace

Clearance between regular

8 pin and bushing

Clearance between link con-

10 tact portion

idjust

Standard size Repair limit

-1 _ug welding,
Triple grouser PC40MRX : 20 r,ebuild or
Thickness of shoe 16
grouser PC45MRX : 24 r,eplace
City pad shoe

Road liner - - Fileolace

-
Thickness of link (press fit- Rrebuild or
14 18.075 12.075
ting portion of bushing) rleplace

Standard size Reverse limit Repair limit it is able to use in

sverse until reach
15 Thickness of bushing ;;I reverse limit. If
had exceeded
6.25 4.55 3.25 ttle repair limit,
r,zplace it.

Tightening torque of shoe 137 k 19.6 Nm {14 f 2 kgm)

16 Fletighten
bolt
-

PC27 - 45MRX- 1 40-29

a
MAINTENANCE STANDARD CONTROL VALVE

CONTROL VALVE
PC27MRX, PCSOMRX-1
(l/6)

SWPO5275

PC27 - 45MRX-1 40-35

0
MAINTENANCE STANDARD CONTROL VALVE

12/6)

boo

A-A SUP05276

40-36 PC27 - 45MRX- 1

a
MAINTENANCE STANDARD CONTROL VALVE

(3/6)

-
u -I-\ -Ebi
kn I tI.35* 1.415Nm
(0.85*0.1

.45Nm
.I5k9m

SWP05277

Unit: mm

PC27 - 45MRX-1 40-37

0
MAINTENANCE STANDARD CONTROL VALVE

q 22.05*2.45Nm
{2.25*0.25kom

m 52.9*5.9Nm

c-c swPo527a

40-38 PC27 - 45MRX- 1

a
MAINTENANCE STANDARD CONTROL VALVE

Unit: mm

No. Check item Criteria Remedy

Standard clearance Repair limit

:re; E;gth Installed Installed Free Installed

‘ressure compensation valve length load length load
1
spring
5.49 N
20.0 x 8.40
IO.56 kg}

120 N
2 Unload valve spring 28.6 x 19.2
{12.2 kg1
Replace
spring if
3 Cooler check valve spring 27.2 x 13.2 damaged or
- deformed

Self pressure reducing 34.6 104N 83.2 N

4 40.5 x 14.3
sequence valve spring {IO.6 kg) - i8.48 kg}
-
N 18.1 N
5 Spool return spring (Breaker) 29.0 x 17.5 I2.30
28.5 22.6 kg1 - {I .80 kg}

Pressure compensation valve 17.0 15.7 N 12.5 N

6 22.2 x 8.40
spring (I.60 kg} - II.28 kg}

PC27 - 45MRX- 1 40-39

0
MAINTENANCE STANDARD CONTROL VALVE

K-K

E-E

H-H
G-G
SWPO5279

Unit: mm

Check item Criteria Remedy

Standard clearance Repair limit

Free length Installed Installed Free Installed
, Check valve spring xOD length load length load
Replace
(Arm, boom)
1.57 N spring if
21.9 x 5.0
1 1513 1 KEkNgl 1 - IO.16 kg} damaged or
deformed
13.7 N 11.0 N
2 Check valve spring (Boom) 13.7 x 7.60 9.90
I Il.40 kg} - {1.12 kg}

40-40 PC27 - 45MRX-1

0
MAINTENANCE STANDARD CONTROL VALVE

J-J

N-N

SWPO5280

Unit: mm

PC27 - 45MRX- 1 40-41

a
MAINTENANCE STANDARD CONTROL VALVE

W6)

-tl- u - ?-I-
-

A-A 9JUOOO31

PC27 - 45MRX-1 40-43

0
MAINTENANCE STANDARD CONTROL VALVE

(3/6)

B-0
(PC35MR-I)

9JUOOO32
Unit: mm

Criteria

44.3 N 35.5 N
4 Junction valve spring 41.1 x 13.8 22.0
(4.52 kg} - (3.62 kg1

40-44 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD CONTROL VALVE

PI/61

22.06*2.45Nm
2.25* 0.25bml

w 53.0* 5.9Nm
(5.4*0.6kPml

,/ c-c \!
9JUOOO33

Unit: mm

No. Check item Criteria Remedy

~
, Pressure compensation valve
spring

Unload valve spring

3
I Cooler check valve spring
I 27.2 x 13.2 21.0
78.8 N
l8.04 kg} -
63.0 N
16.43 kg}
Replace

I I 15.3 N 12.3 N spring if

4 Lift check valve spring 29.0 x 13.3 21.0
{I.56 kg) - il.25 kg} damaged or
deformed
18.1 N
return spring (Breaker) 129.0x 17.5 1 28.5 1 $;;kNgj 1 - (I.80 kg)

17.6 N 14.1 N
6 Throttle valve spring 23.2 x 12.1 15.0 II.80 kg} - II.44 kg)

17.6 N 14.1 N
7 Pressure
spring compensation valve 22.2 x 8 40 18.0 il.80 kg) - II.44 kg)

40.0 N 32.4 N
8 spring
Pressure compensation valve 34 2 x 8.40 25.0 14.10 kg) - 13.30 kg)

PC27 - 45MRX- 1 40-45

0
MAINTENANCE STANDARD CONTROL VALVE

W6)

f 9.8Nm
kB.1

G-G

f 2.45Nm
0.25kml
J-J 9JUOOO34

Unit: mm

No. Check item Criteria Remedy

Standard clearance Repair limit

Free length Installed Installed Free Installed
1 Check valve spring xOD length load length load

1.96 N 1.57 N
13.0 x 6.50 9.0
IO.20 kg) - IO.16 kg1

2.25 N 1.77 N
2 Check valve spring (Boom) 16.4 x 7.50 9.90 Replace
IO.23 kg} - (0.18 kg] spring if
damaged or
1.96 N 1.57 N deformed
21.9 x 5.0 15.8
IO.20 kg) - IO. 16 kg}

3.63 N 2.94 N
7.25 x 5.50 5.0
IO.37 kg1 - IO.30 kg}

61.7 N 49.4 N
5 Logic valve spring 16.3 x 9.20 11.5
I 16.30 kg} - I5.04 kg)

40-46 PC27 - 45MRX- 1

a
MAINTENANCE STANDARD CONTROL VALVE

(6/6)

-
K-K

cc-cc

M-M

Unit: mm

No. Check item Criteria Remedy

Standard clearance Repair limit

Free length Installed Installed Free Installed
, Check valve spring xOD length load length load
Replace
(Bucket, arm, swing) spring if
1.96 N 1.57 N
21.9 x 5.0 15.8 (0.16 kg) damaged or
IO.20 kg} -
deformed
0.98 N 0.78 N
2 Check valve spring (Blade) 15.3 x 6.50 11.8
(1.10 kg1 - IO.08 kg)

PC27 - 45MRK 1 40-47

0
MAINTENANCE STANDARD SWING MOTOR

SWING MOTOR
LMF16
PC27MRX, PC30MRX-1

9Nm
km1

cc= 53.9*9.8Nm
(5.5* lkml SKP02924

Unit: mm
-
No< Check item Criteria Remedy
-
Standard clearance Repair limit
Free length Installed Installed Free Installed
xOD length load length load
1 Timer valve spring I Replace
12.6 x 6.50 10.5 19.6 N 1.47 N spiing if
IO.20 kg1 - IO.15 kg} damaged or
deformed
3.43 N 2.55 N
2 Valve return spring 13.0 x 6.50 7.0
IO.35 kg} - IO.26 kg}

40-48 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD SWING MOTOR

LMF16
PC35MRX. PC40MRX, PC45MRX-1

A-A

9JUOOOO4

Unit: mm
-

!
No Check item Criteria Remedy

Standard clearance Repair limit

Installed Installed Free Installed
FreE IgeEgth length load length load
1 Kmer valve spring I I I Replace
spring if

I
19.6 N 1.47 N
12.6 x 6.50 10.5 damaged or
I (0.20 kg} - IO. 15 kg}
I I
deformed

-
2 Jalve return spring
I
13.0 x 6.50
I
7.0
3.43 N
IO.35 kg} I - I 2.55 N
IO.26 kg}

PC27 - 45MRX- 1 40-49

0
MAINTENANCE STANDARD CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

PC27MRX- 1

SDP03277

Unit: mm

No. Check item Criteria Remedy

Standard size Standard clearance Clearance limit

Clearance between rotor
1 Replace
and shaft 45 0.055 - 0.085 0.090

PC27 - 45MRX- 1 40-57

0
MAINTENANCE STANDARD CENTER SWIVEL JOINT

PC30MRX- 1

-
_
=
-
-

SWPO5281

Unit: mm

No. Check item Criteria Remedy

Standard size Standard clearance Clearance limit

, Clearance between rotor
Replace
and shaft 60 0.055 - 0.085 0.090

40-58 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD CENTER SWIVEL JOINT

PC35MRX, PWOMRX, PC45MRX-1

SVPO6053

Unit: mm

No. Check item Criteria Remedy

Standard size Standard clearance Clearance limit

, zy:hrg? between rotor
Replace
60 0.055 - 0.085 0.090

PC27 - 45MRX- 1 40-59

0
MAINTENANCE STANDARD HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
BOOM CYLINDER
The diagram shows the PC30MRX of canopy specification.

Ln. .U

9JA00797

ARM CYLINDER
The diagram shows the PC30MRX cylinder.

2 4 I 3

9JA00798

BUCKET CYLINDER
The diagram shows the PC30MRX cylinder.

2 4 I 5 3

40-60 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD HYDRAULIC CYLINDER

BOOM SWING CYLINDER

The diagram shows the PCBOMRX canopy specification.

BLADE CYLINDER
The diagram shows the PCBOMRX cylinder.

9JA00801

PC27 - 45MRX-1 40-61

0
MAINTENANCE STANDARD HYDRAULIC CYLINDER

PC27MRX-1 Unit: mm

NO.1 Check item Criteria 1 Remedv

I I
olerance Standard Clearance
CYlinder IStandard size14
Hole clearance limit
+ 0.039
0
+ 0.039
0
learance between + 0.039 “.“LD -
0 0.126 0.426
““I
1 iston rod and
ushing 025 + 0.039 0.025 - r-r476
087 0
025 + 0.039 0.025 -
087 0 n ,‘)I2
025 + 0.039 “.“L.J -
087 0 0.126
025 + 0.039 0.025 - head
no7 n 0.126 0.426

C learance between
! Piston rod support
S haftand bushing

Replace pir
or bushing

Ilearance between
ylinder bottom
upport shaft and
Jshing

Boom 569256.9 Nmf58k5.8 kgm}

(canopy)
Boom 569k56.9 Nm158i5.8 kgm}
(cabin)

Arm 785f76.5 Nm{80i8.0 kgm}

C ylinder head
4 Bucket 637k63.7 Nm(65k6.5 kgm}
ti!ghtening torque
Swing
588t58.8 Nm{60+6.0 kgmj
(canopy)
Swing 588k58.8 Nmt60f6.0 kgm)
(cabin)

Blade 588f58.8 Nmf60f6.0 kgm1

- Retighten
Boom
785i78.5 Nm{80+8.0 kgm) (Width across flats: 46mm)
(canopy)
Boom 785k78.5 Nm{80+8.0 kgm} (Width across flats: 46mm)
(cabin)
Arm 785f78.5 Nm(80f8.0 kgm} (Width across fiats: 46mm)
C ylinder piston fix-
5 inrg nut tightening Bucket 412k41.2 Nm(42f4.2 kgm} (Width across flats: 36mm)
tcrrque
Swing
647G4.7 Nm(66f6.6 kgm) (Width across flats: 41mm)
(canopy)
Swing 647f64.7 NmI66f6.6 kgm} (Width across flats: 41mm)
(cabin)

Blade 785k78.5 NmISOf8.0 kgm) (Width across flats: 46mm)

40-62 PC27 - 45MRX- 1

a
MAINTENANCE STANDARD HYDRAULIC CYLINDER

PC30MRX- 1 Unit: mm
-
No T Check item I Criteria Remedy
Tolerance
Cylinder Standard size
Shaft 1 Hole
Boom - 0.025 Replace
(canopy1 45 - 0.087 cylinder
Boom - 0.025 head
(cabin) 45 - 0.087
Clearance between Arm 40 - 0.025
- 0.087 0
1 aiston rod and
aushing Bucket 40 - 0.025 +0.132 Replace
- 0.087 + 0.006 bushing
!5 + 0.039
>- 0
Replace
+ 0.039
0 cylinder
head
+ 0.039
0

Clearance between
2 piston rod support
shaft and bushing

Replace pin
or bushing

Clearance between
cylinder bottom - +0.142 -
3 Bucket 35 1.0
support shaft and + 0.080
bushing Swing - +0.142 -
40 1.0
(canopy) + 0.080
Swing - +0.142 -
40 1.0
(cabin) + 0.080
- +0.128 -
Blade 45 1.0
+ 0.075
Boom
569k56.9 Nmi58k5.8 kgm1
(canopy)
Boom 569f56.9 NmI58k5.8 kgm)
(cabin)
Arm 677+67.7 Nm(69+6.9 kgm)
Cylinder head
4 Bucket 490+49.0 NmI5w5.0 kgml
tightening torque
Swing
588k58.8 Nm(6ti6.0 kgm)
(canopy)
Swing 588k58.8 Nm(6w6.0 kgml
(cabin)
Blade 588k58.8 Nm(6ti6.0 kgm1
Retighten
Boom 785k78.5 Nm{80+8.0 kgm) (Width across flats: 46mm)
(canopy)
Boom 785k78.5 Nm{80?8.0 kgm) (Width across flats: 46mm)
(cabin)
Arm 1 785k78.5 Nm{80+8.0 kgm) (Width across flats: 46mm)
Cylinder piston fix-
5 ing nut tightening Bucket 785k78.5 Nm(80k8.0 kgm) (Width across flats: 46mm)
torque
Swing
647k64.7 Nm{66f6.6 kgm} (Width across flats: 41mm)
(canopy)
Swing 647f64.7 Nm{66f6.6 kgm} (Width across flats: 41mm)
(cabin)
Blade 785+78.5 Nm(80k8.0 kgm} (Width across flats: 46mm)

PC27 - 45MRX- 1 40-63

0
MAINTENANCE STANDARD HYDRAULIC CYLINDER

PC35MRX-1

Unit: mm
-
NC). T Check item Criteria 1 Remedy

Replace
cylinder
head

Clearance between
1 piston rod and
bushing

Replace
bushing

Clearance between
2 piston rod support
shaft and bushing

Replace pin
or bushing

Clearance between
cylinder bottom
3
support shaft and
bushing

-
Boom 588+58.8 Nm(60f6.0 kgm)
(canopy)
Boom
.. . 588f58.8 Nm(60k6.0 kgm1

Arm 677+67.7 Nmf69f6.9 kgm)

Cylinder head
4
tightening torque
Bucket 677k67.7 Nmi69k6.9 kgm1

Swing 735e73.5 Nmf75k7.5 kgml

-
Blade I 735+73.5 Nmt75k7.5 kgm) 1
Retighten
Boom 785f78.5 Nm{80f8.0 kgm} (Width across flats: 46mm)
(canopy)
Boom 785k78.5 Nm(80f8.0 kgm} (Width across flats: 46mm)
(cabin)

Cylinder piston fix- Arm 1.25kO.13 kNm(127f12.7 kgm) (Width across flats: 50mm)
5 ing nut tightening
torque Bucket 785k78.5 Nm{80*8.0 kgm} (Width across flats: 46mm)

Swing 1.67kO.17 kNm(170+17.0 kgm} (Width across flats: 55mm)

Blade 1.08kO.11 kNm(llO+ll.O kgm} (Width across flats: 50mm)

40-64 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD HYDRAULIC CYLINDER

PWOMRX- 1

Unit: mm

NC Check item Criteria Remedy

-

Replace
cylinder
head

Clearance between
1 piston rod and
bushing

Replace
bushing

(canopy) 50 - 0.209
. “. .__
+ 0.080
“.__, 1.0
0.351
Boom - 0.147 +0.142 0.227 -
(cabin) 50 - 0.209 + 0.080 0.351 1.0

Arm 45 - 0.025 +0.142 0.105 -

Clearance between 1.0
- n ncn
“.“u-t ,nn*n
TV.““” n ,nr
“.L””
piston rod support
-0.170 +0.142 0.250 -
shaft and bushing Bucket 45 1.0
- 0.230 + 0.080 0.372
-nnos “.l_”
sn ld7 ninc- __
- 0.064 + 0.080
- 0.030 +0.174
I I
- 0.076 +O.lOO :place pin
Boom - 0.025 +0.142 bushi ing
I___^__.\
,carl”py,
50 / n no,_,
-Y.““r
Lnnan
TV.““” “.LLd

Boom - 0.025 +0.142 0.105 -

(cabin) 50 - 0.087 + 0.080 0.229 1.0

Clearanc :e L,,
kZ,,%.,__” .~ _nn7c, +n_.147
._ n inK_ __
cylinder bone + 0.080
3
support shaft +0.142
bushing + 0.080
+0.142
, _“.“u-t ,
Lnnan
TV.““” V.&V”

- 0.030 +0.174 0.130 -

Blade 55 1.0
- 0.076 +O.lOO 0.250
Boom 677k67.7 Nm{69+6.9 kgm1
(canopy)
Boom 677k67.7 Nm{69+6.9 kgm)
(cabin)

Arm 726k72.6 Nmt74f7.4 kgm)

Cylinder head
4
tightening torque
Bucket 785f78.5 NmI8ti8.0 kgm)

1 Swing 1 677k67.7 Nm{69+6.9 kgm}

Blade 8631-86.3 NmI88+8.8 kgm)

Retighten
Boom 1.25kO.13 kNm(127f12.7 kgm] (Width across flats: 55mm)
(canopy)
Boom 1.25f0.13 kNm(127k12.7 kgm) (Width across flats: 55mm)
(cabin)

Cylinder piston fix- Arm 1.42kO.14 kNm(145L14.5 kgm} (Width across flats: 55mm)
5 ing nut tightening
torque Bucket 1.08kO.11 kNm(1 IO+1 1.0 kgm} (Width across flats: 46mm)

1 Swing 1 1.67f0.17 kNm(170+17.0 kgm} (Width across flats: 55mm)

I
Blade 1.42kO.14 kNm(145f14.5 kgm} (Width across flats: 55mm)

PC27 - 45MRX- 1 40-65

a
MAINTENANCE STANDARD HYDRAULIC CYLINDER

PC45MRX- 1

Unit: mm

No Check item I
I
Criteria Remedy

1 Cylinder IStandard size]-

nce Sta ndard I Clearance
I , V.IV.. , Hole clearance 1 limit
Boom - 0.025 + 0.039 _ ___ Replace
0.025 -
0.426 cylinder
(canopy) 50 - 0.087 0 n 1%.-
head
- 0.025 1~26 0.426
- 0.087
Clearance between
1 piston rod and - 0.025 0.032 -’
0.551
- 0.087 0.251

c
bushing
- 0.025 0.032 -
0.551
- 0.087as + 0.007 0.251 Replace
- 0.0: 25 +0.167 0.032 - bushing
0.551
- o.of..?7 + 0.007 0.251
- 0.025 + 0.164 0.032 -
0.551
- 0.087 + 0.007 0.251
- 0.147 + 0.142 0.227 -
1.0
0.351
Boom 0.227 -

Clearance between
I--
(cabin) 0.351
1.0

2 piston rod support

shaft and bushing

I
1.0
“LD” Replace pin
I.105 - or bushing
1.0
0.229
I.105 -
1.0
0.229
Clearance between I.105 -
1.0
cylinder bottom 0.229
3
support shaft and
bushing

Boom 677k67.7 Nmf69k6.9 kgm)

(canopy)
Boom 677f67.7 Nmf69f6.9 kgml
(cabin)

Arm 863f86.3 NmI88k8.8 kgm)

Cylinder head
4
tightening torque
Bucket 863586.3 Nmf88f8.8 kgml

Swing 735+73.5 Nmf75f7.5 kgm1

piyr 863k86.3 NmI88t8.8 kgm)

Retighten
Boom 1.25kO.13 kNmI127k12.7 kgm} (Width across flats: 55mm)
(canopy)
Boom 1.25+0.13 kNmI127k12.7 kgml (Width across flats: 55mm)
(cabin)

Cylinder piston fix- Arm 1.67f0.17 kNm{17M17.0 kgm) (Width across flats: 55mm)
5 ing nut tightening
torque Bucket 1.08+0.11 kNm{llO?ll.O kgml (Width across flats: 46mm)

Swing 1.6750.17 kNm{17&17.0 kgm) (Width across flats: 55mm)

[Blade I 1.42f0.14 kNm{145*14.5 kgm} (Width across flats: 55mm)

40-66 PC27 - &MN- 1

0
MAINTENANCE STANDARD WORK EQUIPMENT

Unit: mm

No Check item Criteria Remedy

Tolerance

“In*
90

0.156 -
35MRXI 95 1.0
0.297
bracket -I

-0.025
-0.064
IOMRXI cr\
swing bracket IPC45MRXI LI”

-0.025 +0.142 0.105 -

3 1.0
-0.064 +0.080 0.206

Clearance be-
4 1.0
-0.052
-0.170
of arm and link -0.230 -0.012
t- -0.065

PC27MRX - 0.090 +0.142 0.170 -

-0.130 +0.080 0.272 Replace pin
or bushing
Clearance be- -0.170 0.118-
t$xn,,cnunx?c~~g PC30MRX 35 -0.230 -0.003 0.227
5 1.0
of arm and -0.170 - 0.052 0.118-
bucket PC35MRX -0.209 0.206

PC4OMRX -0.170 -0.012 0.105 -

PC45MRX 45 - 0.230 -0.065 0.218
-
PC27MRX -0.090 +0.142 0.170 -
Clearance be- -0.130 +0.080 0.272
35
meen Connecting PCJOMRX - 0.003 0.118-
6 pin and bushing PCJ5MRX - 0.052 0.227 1.0
of link and link -0.170
PC4OMRX - 0.230 -0.012 0.105 -
PC45MRX 45 -0.065 0.218
-

1
PC27MRX
- 0.090
-0.130
+0.142
+0.080
0.170 -

0.118-
0.272

1.0

I
PC45MRX
PC4OMRX I 45 -0.170
-0.230 -0.012
- 0.065 0.105 0.218
-

-
Clearance be- PC27MRX I -0.090 I I 0.170- I
tween connecting PC30MRX 1 -0.130 1 ,n 147 ( o.272 1 ,..
7”. 0-L
8 pin and bushing Pa5MRX 35
+0.080 0.105 -
of blade and track PcLu)MRX - 0.025
frame PC45MRX - 0.087 0.229
-

PC27 - 45MRX-1 40-69

a
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

DIMENSION OF WORK EQUIPEMENT

1. ARM
PC27MRX-1

1 7

c I(1

B-0 c-c
n
SWPO6141

40-70 PC27 - 45MRX-1

a
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

Unit: mm

PC27MRX-1
No.
Tolerance
Measuring position Standard size
Shaft Hole

- 0.090 +0.090
1 - 0 35 - 0.130 0
Arm 46 +I
0
2
+0.2
Cylinder head 45
0
Boom 124 +0.5
0
3

Arm 123.5 -00.5

- 0.025 +0.090
4 - 0 40
- 0.064 0

5 - 261 ?I

+2
6 - 175.2 0
+2
7 - 259 0

8 - 1,110 *3

9 - 936 +I

10 - 174 fl

11 - 265.5 kO.5

12 - 250.5 zko.5

13 - 200 -

14 -
I 653
I
-

- - 0.090 +0.090
15 0 35
- 0.130 0

16 -
I
I
136
II
+1

- 0.090 +0.090
17 -
0 35
- 0.130 0

Arm 136
-00.5
18
Bushing press fitting 144
I -

Min. 730 -
I I
19
Max

PC27 - 45MRX- 1 40-71

0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

PC30MRX-1

IO Y
1

6 7

_) 151_ _) IJj
z-z SWPO5289

40-72 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

Unit: mm

PC30MRX-1
No.
Tolerance
Measuring position Standard size
Shaft Hole

- +0.142 +0.090
1 0 40
+0.080 0

2
I Arm I I
+0.2
Cylinder head 50
0
Boom 124 +0.5
0
3

Arm 123.5 J.5

4 - 0 40 +0.142 +0.090
+0.080 0

5
I - I 256.3
I
+1

+2
6 - 138
0
+2
7 - 263
0

8 - 1,260 +3

9 - 1,006.6 fl

10 - 163.6 fl

11 - 279.3 rto.5

12 - 256 f0.5

13 - 194.6 -

14 - 754 -

15 - 0 35 - 0.170 -0.050
- 0.230 - 0.089

17 - 0 35 - 0.170 -0.050
- 0.230 - 0.089

Arm - -

18
Bushing press fitting 145 -

PC27 - 45MRX-1 40-73

0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

PC35MRX, PC40MRX, PC45MRX-1

The diagram shows the PC40MRX.

B-
4

A-A c-c 9JA00802

40-74 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

Unit: mm

PC35MRX-1
No.
Tolerance
Measuring position Standard size
Shaft Hole
1 - 0 40 - 0.025 +0.090
- 0.064 0
Arm 50.5 +l
0
2
Cylinder head 50 -:.5
Boom 130 +0.5
0
3
Arm 130 -0.3
-1.0
4 - 040 - 0.025 +0.090
- 0.064 0

5 I - I 161.5 I *I

- +I
6 108.2 0
I

8 - 1,345.7 -
I I I

9 I - I 1.193.1 I fl

10 I - I 163.6
I
+I

11
I - I 280
I
+0.5

12 I -

13 I - I 194.6
I
f0.5

14 - 754 -
I I I
15 - 0 35 - 0.170 - 0.050
- 0.209 - 0.089
n
1 Link -ii!?
I I - -
16 I
+1

Arm 143.5 _00.5

18
Bucket 145 *I

Min. 780 +1.5

19
Max 1,270 -

PC27 - 45MRX- 1 40-75

a
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

PC40MRX-1
No.
Tolerance
Measuring position Standard size
Shaft Hole
I I I I

1 - 0 45 - 0.025 +O.l
- 0.064 0
+l

2
I Arm side 55.5
0

Cylinder head 55
J.5

+0.5
Boom side 163
I 0
3
I
-0.3
Arm side 163
-1.0
I I I

- 0.025 +O.l
4 - 0 50
- 0.064 0

+I
6 - 153.7
0
+I
7 - 347.7
0

8 1,371.4 -
I

9 I - I 1,395.6
I
*1

10 I - I 193.5 I fl

11 I - I 330
I
f0.5

12 - 303 f0.5
I I I

13 I - 230.3

14 - 871 -

-0.170 - 0.050
15 - 045 - 0.230 - 0.089
+0.7
Link 168
+0.2
16
Bucket 170 fl

- 0.170 - 0.050
17 - 0 45 - 0.230 - 0.089
Arm 168 +0.7
+0.2
18

I Bucket
I
I
I
170
I
I
fl

II Max I
I
1,480
II -

40-76 PC27 - 45MRX- 1

a
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

PC45MRX-1
No.
Tolerance
Measuring position Standard size
Shaft Hole

1
I
- 0 45
I - 0.025
- 0.064 I
+O.l
0

Arm side +l
55.5
0
2

Cylinder head 55 -00.5

Boom side 163 +0.5

0
3
Arm side 163 -0.3
-1.0

4 - 0 50 - 0.025 +O.l
- 0.064 0

5 I - I 176.6 I +1

- +I
6 149.9
0

- +l
7 373
0

8 - 1,472.4 -

9 - 1,389.6 fl

10 - 193.6 +I

11 - 330 f0.5

12 - 303 kO.5

13 - 230.3 *0.5
I I I
14 - 871 -

15 - 045 - 0.170 - 0.050

- 0.230 - 0.089
Link 168 +0.7
+0.2
16
Bucket 170 +1

17 - 0 45 - 0.170 - 0.050
- 0.230 - 0.089

Arm 168 +0.7

+0.2
18
Bucket 170 +I

Min. 900 +1.5

19
Max 1,480 -

PC27 - 45MRX- 1 40-77

0
 MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

2. BUCKET PORTION
PC27MRX-1

A-A

SWPO6142

40-78 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

Unit: mm

PC27MRX:l
No.
Measuring position Standard size Tolerance

1 - 200 -

2 - 10 -

3 - 200.3 -

4 - 657.3 -

5 - 28.8 -

6 - 40” 6’ -

7 - 40’ 6’ -

8 - 0 35 +0.090
0
+2
9 - 145
0

10 51 -

11 - 36 -

12 - 221 +1

13 - 0 13.5 -

14 - 0 60 -

15 - 0 60 -

16 - 58.2 -

17 - 31.4 -

18 - R42 -

19 - R42 -

PC27 - 45MRX- 1 40-79

0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

PC30MRX-1

A-A

40-80 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

Unit: mm

PC30MRX-1
No.
Measuring position Standard size Tolerance

1 - 194 -

15 - 0 60 -

16 - 45.7 -

17 34.6 -

18 - R40 -

19 - R40 -

PC27 - 45MRX- 1 40-81

0
 MAINTENANCE STANDARD
DIMENSION OF WORK EQUIPEMENT

PC35MRX-1

A-A

9JA00804

40-82 PC27 - 45MRX- 1

a
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

Unit: mm

PC35MRX-1
No.
Measuring position Standard size Tolerance

1 - 194.6 kO.5

2 - 87.4 -

3 - 55.6 -

4 - 553.9 -

5 - 567.5 -

6 - 40
I

7 - 40 -

8 - 45” -

I -
10 - 13.5 -

11 - 145 &I

12 - 51 -

13 - 36 -

14 - 221 +I

15 - 0 60 -

16 - 0 60 -

17 - 0 35 - 0.050
- 0.089

PC27 - 45MRX- 1 40-83

0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

PC40MRX, PC45MRX-1
This drawing shows PC40MRX.

A-A
9JAOOB05

40-84 PC27 - 45MRX- 1

0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPEMENT

Unit: mm

PC40MRX. 45MRX-1
No.
Measuring position Standard size Tolerance

1 - 230.3 kO.5

- -

3 - 45 -

4 - 719.6 -

5 - 55 -

6 - 55 -

7 - 45” -

8 - 45” -

9
I - 13.5
I -
10 - 170 fl

11 - 60 -

12 - 42 -

13 - 258 +I

14
I
- 0 85
1 -
15 I
- 0 85 I -
- - 0.050
16 045
I - 0.089

PC27 - 45MRX- 1 40-85

0
HYDRAULIC CIRCUIT DIAGRAM
PC27MRX-1

PC27 - 45MRX-1 90-3

HYDRAULIC CIRCUIT DIAGRAM
PC30MRX-1

PC27 - 45MRX-1 90-5

HYDRAULIC CIRCUIT DIAGRAM
PC35MRX-1

PC27 - 45MRX-1 90-7

ELECTRICAL CIRCUIT DIAGRAM
CAB SPECIFICATION
PC27, 30MRX-1

PC27 - 45MRX-1 90-15