Komatsu GALEO PC300LL-7L Hydraulic Excavator Shop Manual PDF
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Komatsu GALEO PC300LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
SERIAL NUMBERS PC300LL-7L A85001 and UP
Description
Komatsu GALEO PC300LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
FILE DETAILS:
Komatsu GALEO PC300LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
Language : English
Pages : 676
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:
Komatsu GALEO PC300LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
SERIAL NUMBERS PC300LL-7L A85001 and UP
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
PREPARATIONS FOR WORK:
PRECAUTIONS DURING WORK :
TABLE OF CONTENTS:
Komatsu GALEO PC300LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
SERIAL NUMBERS PC300LL-7L A85001 and UP
MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 5
SAFETY NOTICE 5
FOREWARD 7
GENERAL 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 9
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 17
CONVERSION TABLES 18
UNITS 23
01 GENERAL 25
DIMENSION DRAWINGS 26
DIMENSIONS 26
WORKING RANGES 28
SPECIFICATIONS 30
WEIGHT TABLE 33
POWERED CAB RISER TILT UNIT TARGETS 35
FUEL COOLANT AND LUBRICANTS 36
PC300LL-7L 36
10 STRUCTURE AND FUNCTION 37
ENGINE RELATED PARTS 39
RADIATOR OIL COOLER AFTERCOOLER 40
FINAL DRIVE SYSTEM 42
PC300LL-7L 42
SWING MACHINERY 45
SWING CIRCLE 48
TRACK FRAME RECOIL SPRING 50
PC300LL-7L 50
IDLER 51
TRACK ROLLER 53
TRACK SHOE 54
TRIPLE GROUSER SHOE 56
HYDRAULIC EQUIPMENT 57
HYDRAULIC TANK 59
HYDRAULIC PUMP 60
HPV125 + 125 60
LS VALVE 65
PC VALVE 65
LS(PC)-EPC VALVE 77
VARIABLE VOLUME VALVE 80
CONTROL VALVE 82
MAIN RELIEF VALVE 93
VARIABLE PRESSURE COMPENSATION VALVE 94
CLSS 95
SELF PRESSURE REDUCING VALVE 98
SWING MOTOR 101
SUCTION-SAFETY VALVE 104
SWING BRAKE 105
CENTER SWIVEL JOINT 106
PC300LL-7L 107
MOTOR OPERATION 109
PARKING BRAKE OPERATION 111
BRAKE VALVE OPERATION 112
TRAVEL JUNCTION VALVE 116
TRAVEL PPC SHUTTLE VALVE 118
VALVE CONTROL 122
WORK EQUIPMENT SWING PPC VALVE 123
TRAVEL PPC VALVE 127
ATTACHMENT SOLENOID VALVE 136
PPC ACCUMULATOR 138
BOOM HYDRAULIC DRIFT PREVENTION VALVE 139
QUICK RETURN VALVE 145
LIFT CHECK VALVE 147
HYDRAULIC CYLINDER 148
BOOM CYLINDER 148
ARM CYLINDER 148
BUCKET CYLINDER 149
WORK EQUIPMENT 150
DIMENSION OF ARM 152
DIMENSION OF BUCKET 154
AIR CONDITIONER 156
PIPING 156
ENGINE CONTROL 157
FUEL CONTROL DIAL 159
GOVERNOR MOTOR 160
ENGINE THROTTLE AND PUMP CONTROLLER 161
INPUT AND OUTPUT SIGNALS 162
ELECTRONIC CONTROL SYSTEM 163
TOTAL SYSTEM DIAGRAM 164
MULTI MONITOR SYSTEM 187
MONITOR PANEL 188
MONITOR CONTROL, DISPLAY PORTION /MONITOR PORTION 190
MAINTENANCE FUNCTION 201
SENSORS 206
ENGINE OIL LEVEL SENSOR 206
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE) 206
COOLANT TEMPERATURE SENSOR 207
HYDRAULIC OIL TEMPERATURE SENSOR 207
FUEL LEVEL SENSOR 208
AIR CLEANER CLOGGING SENSOR 208
CAB RISER AND RELATED PARTS 209
POWER CONTROL 210
STRESS TARGETS FOR CAB RISER KIT 211
CAB RISER HYDRAULIC SYSTEM 212
20 TESTING, ADJUSTING AND TROUBLESHOOTING 213
STANDARD VALUE TABLES 215
ENGINE RELATED 215
CHASSIS RELATED 216
SERVICE TOOLS 224
ENGINE 224
AIR BOOST PRESSURE 224
AIR COMPRESSOR BELT TENSION 224
BLOW-BY PRESSURE 224
COMPRESSION PRESSURE 224
ENGINE OIL PRESSURE 224
ENGINE RPM 224
ENGINE SPEED SENSOR 225
EXHAUST GAS COLOR 225
FUEL INJECTION TIMING 225
VALVE CLEARANCE 225
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE 226
SWING CIRCLE BEARINGS 226
TRACK SHOE TENSION 227
SPROCKET 228
OIL PRESSURE 228
WORK EQUIPMENT, SWING AND TRAVEL 228
CONTROL CIRCUIT 233
PUMP PC CONTROL CIRCUIT 234
PUMP LS CONTROL CIRCUIT 237
ATTACHMENT SOLENOID VALVE OUTPUT 241
ATTACHMENT PPC VALVE OUTPUT 244
WORK EQUIPMENT AND SWING PPC VALVE 245
WORK EQUIPMENT, HYDRAULIC DRIFT LOCATIONS 245
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT 246
BOOM AND BUCKET CYLINDERS 246
BOOM LOCK VALVE 246
ARM CYLINDER 247
PPC VALVE 247
OIL LEAKAGE AMOUNT 249
BOOM CYLINDER 249
ARM CYLINDER 249
BUCKET CYLINDER 250
SWING MOTOR 250
TRAVEL MOTOR 250
AIR BLEEDING OF VARIOUS PARTS 251
DIODE INSPECTION PROCEDURES 253
MULTI-MONITOR PANEL 254
MONITOR PANEL FUNCTIONS 255
OPERATOR’S MENU AND DISPLAY (OUTLINE) 256
TABLE FOR SERVICE AND FAILURE CODE NOS 261
SERVICE MENU 263
WAY OF SWITCHING TO SERVICE MENU 263
TABLE FOR MONITORING ITEMS 266
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARTIONS 278
PM TUNE SERVICE 279
TROUBLESHOOTING (GENERAL) 283
POINTS TO REMEMBER WHEN TROUBLESHOOTING 284
SEQUENCE OF EVENTS IN TROUBLESHOOTING 286
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 287
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 287
HANDLING CONTROL BOX 292
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS 293
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 294
CHECKS BEFORE TROUBLESHOOTING 296
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS 297
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO 298
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 301
T-ADAPTER TABLE 325
TROUBLESHOOTING ELECTRICAL SYSTEM (E MODE) 329
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 331
ABNORMALITY RETURNS TO NORMAL BY ITSELF 331
USER CODE MEMORY RETENTION FUNCTION 331
INFORMATION CONTAINED IN TESTING PROCEDURES 332
(E101) 334
ABNORMAL DATA IN ERROR HISTORY 334
(E112) 336
SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION 336
(E113) 338
SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION 338
(E114) 340
SHORT OR OPEN IN WINDOW WASHER SYSTEM 340
(E115) 342
ABNORMAL WINDSHIELD WIPER MOTION 342
(E116) 344
ABNORMALITY IN PARKING WIPER ARM 344
(E201) 346
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID 346
(E203) 348
SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM 348
(E204) 350
SHORT IN MERGE/DIVIDE SOLENOID 350
(E205) 352
SHORT IN 2 STAGE RELIEF SOLENOID 352
(E206) 354
SHORT IN TRAVEL SPEED SHIFT SOLENOID 354
(E211) 356
OPEN IN TRAVEL INTERLOCKING SOLENOID 356
(E213) 358
OPEN IN SWING PARKING BRAKE SOLENOID 358
(E214) 360
OPEN OF MERGE/DIVIDE SOLENOID 360
(E215) 362
OPEN IN 2 STAGE RELIEF SOLENOID 362
(E216) 364
OPEN IN TRAVEL SPEED SOLENOID 364
(E217) 366
ABNORMAL INPUT FOR MODEL CODE 366
(E218) 368
OPEN IN S-NET SIGNAL 368
(E222) 370
SHORT IN LS-EPC SOLENOID 370
(E223) 372
OPEN IN LS-EPC SOLENOID SYSTEM 372
(E224) 374
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL 374
(E225) 376
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL 376
(E226) 378
ABNORMAL PRESSURE SENSOR POWER SUPPLY 378
(E227) 380
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER 380
(E228) 382
SHORT IN ATTACHMENT RETURN SWITCHING RELAY 382
(NO CODE) 384
SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM 384
(NO CODE) 387
OPEN IN CAB TILT SYSTEM 387
(E232) 389
SHORT IN PC-EPC SOLENOID 389
(E233) 391
OPEN IN PC-EPC SOLENOID SYSTEM 391
(E238) 393
OPEN IN ATTACHMENT RETURN SWITCH RELAY 393
(E245) 395
SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM 395
(E246) 397
OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM 397
(E256) 399
INCORRECT NON-VOLATILE MEMORY DATA 399
(E304) 401
SHORT IN ENGINE STOP SOLENOID SYSTEM 401
(E314) 403
OPEN IN ENGINE STOP SOLENOID SYSTEM 403
(E306) 405
ABNORMAL GOVERNOR POTENTIOMETER SIGNALS 405
(E308) 407
ABNORMAL FUEL DIAL SIGNALS 407
(E315) 409
SHORT IN BATTERY RELAY SYSTEM 409
(E316) 411
STEP OUT IN GOVERNOR MOTOR 411
(E317) 413
OPEN IN GOVERNOR MOTOR PHASE “A” AND “B” 413
(E318) 415
SHORT IN GOVERNOR MOTOR PHASE “A” AND “B” 415
(E501) 417
MODEL SELECTION FUNCTION NOT PROVIDED 417
(E502) 418
MODEL SELECTING SIGNAL FAULT 418
(AA10NX) 419
AIR CLEANER CLOG INDICATOR FAILURE 419
(AB00KE) 420
LOW CHARGING VOLTAGE INDICATED 420
(B@BAZG) 422
ABNORMAL ENGINE OIL PRESSURE 422
(B@BAZK) 423
ABNORMAL ENGINE OIL LEVEL 423
(B@BCNS) 424
ENGINE COOLANT INDICATING OVERHEAT CONDITION 424
(B@BCZK) 425
ABNORMAL COOLANT LEVEL INDICATION 425
(B@HANS) 426
HYDRAULIC OIL OVERHEAT INDICATION 426
TROUBLESHOOTING MONITOR ELECTRICAL SYSTEM (E MODE) 427
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 428
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF 428
USER CODE MEMORY RETENTION FUNCTION 428
INFORMATION CONTAINED IN TESTING PROCEDURES 429
(E-1) 431
ENGINE WILL NOT CRANK 431
(E-2) 433
ENGINE STOPS WHILE IN OPERATION 433
(E-3) 435
ENGINE SPEED IRREGULAR, OR HUNTING 435
(E-4) 437
ENGINE DOES NOT SHUT DOWN 437
(E-5) 439
AUTO DECELERATOR DOES NOT WORK 439
(E-6) 440
AUTO ENGINE WARM UP DEVICE DOES NOT WORK 440
(E-7) 441
COLD START PREHEATER DOES NOT WORK 441
(E-8) 443
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE 443
(E-9) 445
ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE 445
(E-10) 447
NO DISPLAY ON MONITOR PANEL 447
(E-11) 449
PART OF DISPLAY ON MONITOR PANEL IS MISSING 449
(E-12) 450
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL 450
(E-13) 451
FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL 451
(E-14) 453
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 453
(E-15) 455
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY 455
(E-16) 457
FUEL GAUGE DOES NOT DISPLAY CORRECTLY 457
(E-17) 459
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY 459
(E-18) 461
WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS 461
(E-19) 463
WINDSHIELD WIPER DOES NOT WORK 463
(E-20) 465
ALARM BUZZER CANNOT BE CANCELLED 465
(E-21) 467
BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR 467
(E-22) 469
BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR 469
(E-23) 471
ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR 471
(E-24) 473
ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR 473
(E-25) 475
BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR 475
(E-26) 477
BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR 477
(E-27) 479
SWING NOT CORRECTLY DISPLAYED ON MONITOR 479
(E-28) 481
TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR 481
(E-29) 483
TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR 483
(E-30) 485
SERVICE NOT CORRECTLY DISPLAYED ON MONITOR 485
(E-31) 487
AIR CONDITIONER SYSTEM DOES NOT WORK 487
(E-32) 491
TRAVEL ALARM DOES NOT SOUND 491
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 495
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 497
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 500
(H-1) 501
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW 501
(H-2) 502
ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS 502
(H-3) 503
NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT 503
(H-4) 503
ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP 503
(H-5) 504
AUTO-DECELERATOR DOES NOT WORK 504
(H-6) 504
FINE CONTROL MODE DOES NOT FUNCTION 504
(H-7) 505
BOOM MOVES SLOWLY OR LACKS POWER 505
(H-8) 506
ARM MOVES SLOWLY OR LACKS POWER 506
(H-9) 507
BUCKET MOVES SLOWLY OR LACKS POWER 507
(H-10) 508
WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION 508
(H-11) 509
WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT 509
(H-12) 510
WORK EQUIPMENT HAS EXCESSIVE LAG TIME 510
(H-13) 511
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT 511
(H-14) 511
ONE-TOUCH POWER MAX SWITCH DOES NOT OPERATE 511
(H-15) 511
IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY 511
(H-16) 512
IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY 512
(H-17) 512
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY 512
(H-18) 513
MACHINE SWERVES WHEN TRAVELING 513
(H-19) 514
MACHINE TRAVELS SLOWLY 514
(H-20) 515
MACHINE CANNOT BE STEERED EASILY OR LACKS POWER 515
(H-21) 516
TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING 516
(H-22) 516
TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY) 516
(H-23) 517
MACHINE DOES NOT SWING 517
(H-24) 518
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW 518
(H-25) 519
EXCESSIVE OVERRUN WHEN STOPPING SWING 519
(H-26) 520
THERE IS A SUDDEN SHOCK WHEN STOPPING SWING 520
(H-27) 520
ABNORMAL NOISE CAUSED WHEN STOPPING SWING 520
(H-28) 521
SWING NATURAL DRIFT IS EXCESSIVE 521
30 DISASSEMBLY AND ASSEMBLY 523
METHOD OF USING MANUAL 525
PRECAUTIONS DURING OPERATION 527
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 527
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 528
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 529
OTHER PRECAUTIONS 529
SPECIAL TOOL LIST 530
SKETCHES OF SPECIAL TOOLS 533
CONNECTOR REPAIR PROCEDURES 535
CONTACT TERMINAL REMOVAL (HD30 TYPE) 535
STRIPING INSULATION 536
CRIMPING CONTACT TERMINAL (HD30 TYPE) 537
INSERTION OF CONTACT TERMINAL (HD30 TYPE) 538
CONTACT TERMINAL REMOVAL (DT TYPE) 539
STRIPING INSULATION 540
CRIMPING CONTACT TERMINAL (DT TYPE) 541
INSERTION OF CONTACT TERMINAL (DT TYPE) 542
ENGINE 543
ALTERNATOR 543
CYLINDER HEAD 543
ENGINE FRONT SEAL 543
ENGINE OIL COOLER 543
ENGINE REAR SEAL 543
FUEL INJECTION PUMP 543
NOZZLE HOLDER 543
STARTING MOTOR 543
THERMOSTAT 543
TURBOCHARGER 543
WATER PUMP 543
RADIATOR 544
REMOVAL 544
INSTALLATION 545
HYDRAULIC OIL COOLER 546
REMOVAL 546
INSTALLATION 547
ENGINE AND HYDRAULIC PUMPS 548
REMOVAL 548
INSTALLATION 552
FINAL DRIVE 553
REMOVAL 553
INSTALLATION 553
DISASSEMBLY 554
ASSEMBLY 558
TRAVEL MOTOR 564
DISASSEMBLY 564
ASSEMBLY 568
SWING MOTOR 578
REMOVAL 578
INSTALLATION 578
DISASSEMBLY 579
ASSEMBLY 581
SWING MACHINERY 588
REMOVAL 588
INSTALLATION 588
DISASSEMBLY 589
ASSEMBLY 592
IDLER AND RECOIL SPRING 597
REMOVAL 597
INSTALLATION 597
IDLER 598
RECOIL SPRING 602
TRACK ROLLER 604
REMOVAL 604
INSTALLATION 604
DISASSEMBLY 605
ASSEMBLY 606
SPROCKET 609
REMOVAL 609
INSTALLATION 609
TRACK SHOE 610
EXPANSION OF TRACK SHOE 610
ASSEMBLY 611
SWING CIRCLE 612
REMOVAL 612
INSTALLATION 612
REVOLVING FRAME 613
REMOVAL 613
INSTALLATION 615
CENTER SWIVEL JOINT 616
REMOVAL 616
INSTALLATION 617
DISASSEMBLY 618
ASSEMBLY 618
HYDRAULIC TANK 619
REMOVAL 619
INSTALLATION 620
CONTROL VALVE 621
REMOVAL 621
INSTALLATION 623
REPLACING PRESSURE COMPENSATION VALVE SEAL 624
ASSEMBLY 625
HYDRAULIC PUMP 626
REMOVAL 626
INSTALLATION 628
INPUT SHAFT OIL SEAL 629
WORK EQUIPMENT PPC VALVE 630
ASSEMBLY 630
TRAVEL PPC VALVE 631
ASSEMBLY 631
HYDRAULIC CYLINDER 632
DISASSEMBLY 632
ASSEMBLY 634
WORK EQUIPMENT 638
REMOVAL 638
INSTALLATION 639
AIR CONDITIONER 641
REMOVAL 641
INSTALLATION 644
COUNTERWEIGHT 645
REMOVAL 645
INSTALLATION 645
OPERATOR’S CAB 646
REMOVAL 646
INSTALLATION 648
MONITOR 649
REMOVAL 649
INSTALLATION 649
GOVERNOR PUMP CONTROLLER 650
REMOVAL 650
INSTALLATION 650
90 OTHERS 651
ELECTRICAL 653
ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 3) FOLDOUT 1 653
ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 3) FOLDOUT 2 655
ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 3) FOLDOUT 3 657
ELECTRICAL DIAGRAM 2/4 (SHEET 1 OF 1) FOLDOUT 4 659
ELECTRICAL DIAGRAM 3/4 (SHEET 1 OF 2) FOLDOUT 5 661
ELECTRICAL DIAGRAM 3/4 (SHEET 2 OF 2) FOLDOUT 6 663
ELECTRICAL DIAGRAM 4/4 (SHEET 1 OF 2) FOLDOUT 7 665
ELECTRICAL DIAGRAM 4/4 (SHEET 2 OF 2) FOLDOUT 8 667
HYDRAULIC 669
HYDRAULIC DIAGRAM (SHEET 1 OF 3) FOLDOUT 9 669
HYDRAULIC DIAGRAM (SHEET 2 OF 3) FOLDOUT 10 671
HYDRAULIC DIAGRAM (SHEET 3 OF 3) FOLDOUT 11 673
MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 5
SAFETY NOTICE 5
FOREWARD 7
GENERAL 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 9
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 17
CONVERSION TABLES 18
UNITS 23
01 GENERAL 25
DIMENSION DRAWINGS 26
DIMENSIONS 26
WORKING RANGES 28
SPECIFICATIONS 30
WEIGHT TABLE 33
POWERED CAB RISER TILT UNIT TARGETS 35
FUEL COOLANT AND LUBRICANTS 36
PC300LL-7L 36
10 STRUCTURE AND FUNCTION 37
ENGINE RELATED PARTS 39
RADIATOR OIL COOLER AFTERCOOLER 40
FINAL DRIVE SYSTEM 42
PC300LL-7L 42
SWING MACHINERY 45
SWING CIRCLE 48
TRACK FRAME RECOIL SPRING 50
PC300LL-7L 50
IDLER 51
TRACK ROLLER 53
TRACK SHOE 54
TRIPLE GROUSER SHOE 56
HYDRAULIC EQUIPMENT 57
HYDRAULIC TANK 59
HYDRAULIC PUMP 60
HPV125 + 125 60
LS VALVE 65
PC VALVE 65
LS(PC)-EPC VALVE 77
VARIABLE VOLUME VALVE 80
CONTROL VALVE 82
MAIN RELIEF VALVE 93
VARIABLE PRESSURE COMPENSATION VALVE 94
CLSS 95
SELF PRESSURE REDUCING VALVE 98
SWING MOTOR 101
SUCTION-SAFETY VALVE 104
SWING BRAKE 105
CENTER SWIVEL JOINT 106
PC300LL-7L 107
MOTOR OPERATION 109
PARKING BRAKE OPERATION 111
BRAKE VALVE OPERATION 112
TRAVEL JUNCTION VALVE 116
TRAVEL PPC SHUTTLE VALVE 118
VALVE CONTROL 122
WORK EQUIPMENT SWING PPC VALVE 123
TRAVEL PPC VALVE 127
ATTACHMENT SOLENOID VALVE 136
PPC ACCUMULATOR 138
BOOM HYDRAULIC DRIFT PREVENTION VALVE 139
QUICK RETURN VALVE 145
LIFT CHECK VALVE 147
HYDRAULIC CYLINDER 148
BOOM CYLINDER 148
ARM CYLINDER 148
BUCKET CYLINDER 149
WORK EQUIPMENT 150
DIMENSION OF ARM 152
DIMENSION OF BUCKET 154
AIR CONDITIONER 156
PIPING 156
ENGINE CONTROL 157
FUEL CONTROL DIAL 159
GOVERNOR MOTOR 160
ENGINE THROTTLE AND PUMP CONTROLLER 161
INPUT AND OUTPUT SIGNALS 162
ELECTRONIC CONTROL SYSTEM 163
TOTAL SYSTEM DIAGRAM 164
MULTI MONITOR SYSTEM 187
MONITOR PANEL 188
MONITOR CONTROL, DISPLAY PORTION /MONITOR PORTION 190
MAINTENANCE FUNCTION 201
SENSORS 206
ENGINE OIL LEVEL SENSOR 206
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE) 206
COOLANT TEMPERATURE SENSOR 207
HYDRAULIC OIL TEMPERATURE SENSOR 207
FUEL LEVEL SENSOR 208
AIR CLEANER CLOGGING SENSOR 208
CAB RISER AND RELATED PARTS 209
POWER CONTROL 210
STRESS TARGETS FOR CAB RISER KIT 211
CAB RISER HYDRAULIC SYSTEM 212
20 TESTING, ADJUSTING AND TROUBLESHOOTING 213
STANDARD VALUE TABLES 215
ENGINE RELATED 215
CHASSIS RELATED 216
SERVICE TOOLS 224
ENGINE 224
AIR BOOST PRESSURE 224
AIR COMPRESSOR BELT TENSION 224
BLOW-BY PRESSURE 224
COMPRESSION PRESSURE 224
ENGINE OIL PRESSURE 224
ENGINE RPM 224
ENGINE SPEED SENSOR 225
EXHAUST GAS COLOR 225
FUEL INJECTION TIMING 225
VALVE CLEARANCE 225
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE 226
SWING CIRCLE BEARINGS 226
TRACK SHOE TENSION 227
SPROCKET 228
OIL PRESSURE 228
WORK EQUIPMENT, SWING AND TRAVEL 228
CONTROL CIRCUIT 233
PUMP PC CONTROL CIRCUIT 234
PUMP LS CONTROL CIRCUIT 237
ATTACHMENT SOLENOID VALVE OUTPUT 241
ATTACHMENT PPC VALVE OUTPUT 244
WORK EQUIPMENT AND SWING PPC VALVE 245
WORK EQUIPMENT, HYDRAULIC DRIFT LOCATIONS 245
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT 246
BOOM AND BUCKET CYLINDERS 246
BOOM LOCK VALVE 246
ARM CYLINDER 247
PPC VALVE 247
OIL LEAKAGE AMOUNT 249
BOOM CYLINDER 249
ARM CYLINDER 249
BUCKET CYLINDER 250
SWING MOTOR 250
TRAVEL MOTOR 250
AIR BLEEDING OF VARIOUS PARTS 251
DIODE INSPECTION PROCEDURES 253
MULTI-MONITOR PANEL 254
MONITOR PANEL FUNCTIONS 255
OPERATOR’S MENU AND DISPLAY (OUTLINE) 256
TABLE FOR SERVICE AND FAILURE CODE NOS 261
SERVICE MENU 263
WAY OF SWITCHING TO SERVICE MENU 263
TABLE FOR MONITORING ITEMS 266
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARTIONS 278
PM TUNE SERVICE 279
TROUBLESHOOTING (GENERAL) 283
POINTS TO REMEMBER WHEN TROUBLESHOOTING 284
SEQUENCE OF EVENTS IN TROUBLESHOOTING 286
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 287
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 287
HANDLING CONTROL BOX 292
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS 293
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 294
CHECKS BEFORE TROUBLESHOOTING 296
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS 297
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO 298
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 301
T-ADAPTER TABLE 325
TROUBLESHOOTING ELECTRICAL SYSTEM (E MODE) 329
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 331
ABNORMALITY RETURNS TO NORMAL BY ITSELF 331
USER CODE MEMORY RETENTION FUNCTION 331
INFORMATION CONTAINED IN TESTING PROCEDURES 332
(E101) 334
ABNORMAL DATA IN ERROR HISTORY 334
(E112) 336
SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION 336
(E113) 338
SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION 338
(E114) 340
SHORT OR OPEN IN WINDOW WASHER SYSTEM 340
(E115) 342
ABNORMAL WINDSHIELD WIPER MOTION 342
(E116) 344
ABNORMALITY IN PARKING WIPER ARM 344
(E201) 346
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID 346
(E203) 348
SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM 348
(E204) 350
SHORT IN MERGE/DIVIDE SOLENOID 350
(E205) 352
SHORT IN 2 STAGE RELIEF SOLENOID 352
(E206) 354
SHORT IN TRAVEL SPEED SHIFT SOLENOID 354
(E211) 356
OPEN IN TRAVEL INTERLOCKING SOLENOID 356
(E213) 358
OPEN IN SWING PARKING BRAKE SOLENOID 358
(E214) 360
OPEN OF MERGE/DIVIDE SOLENOID 360
(E215) 362
OPEN IN 2 STAGE RELIEF SOLENOID 362
(E216) 364
OPEN IN TRAVEL SPEED SOLENOID 364
(E217) 366
ABNORMAL INPUT FOR MODEL CODE 366
(E218) 368
OPEN IN S-NET SIGNAL 368
(E222) 370
SHORT IN LS-EPC SOLENOID 370
(E223) 372
OPEN IN LS-EPC SOLENOID SYSTEM 372
(E224) 374
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL 374
(E225) 376
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL 376
(E226) 378
ABNORMAL PRESSURE SENSOR POWER SUPPLY 378
(E227) 380
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER 380
(E228) 382
SHORT IN ATTACHMENT RETURN SWITCHING RELAY 382
(NO CODE) 384
SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM 384
(NO CODE) 387
OPEN IN CAB TILT SYSTEM 387
(E232) 389
SHORT IN PC-EPC SOLENOID 389
(E233) 391
OPEN IN PC-EPC SOLENOID SYSTEM 391
(E238) 393
OPEN IN ATTACHMENT RETURN SWITCH RELAY 393
(E245) 395
SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM 395
(E246) 397
OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM 397
(E256) 399
INCORRECT NON-VOLATILE MEMORY DATA 399
(E304) 401
SHORT IN ENGINE STOP SOLENOID SYSTEM 401
(E314) 403
OPEN IN ENGINE STOP SOLENOID SYSTEM 403
(E306) 405
ABNORMAL GOVERNOR POTENTIOMETER SIGNALS 405
(E308) 407
ABNORMAL FUEL DIAL SIGNALS 407
(E315) 409
SHORT IN BATTERY RELAY SYSTEM 409
(E316) 411
STEP OUT IN GOVERNOR MOTOR 411
(E317) 413
OPEN IN GOVERNOR MOTOR PHASE “A” AND “B” 413
(E318) 415
SHORT IN GOVERNOR MOTOR PHASE “A” AND “B” 415
(E501) 417
MODEL SELECTION FUNCTION NOT PROVIDED 417
(E502) 418
MODEL SELECTING SIGNAL FAULT 418
(AA10NX) 419
AIR CLEANER CLOG INDICATOR FAILURE 419
(AB00KE) 420
LOW CHARGING VOLTAGE INDICATED 420
(B@BAZG) 422
ABNORMAL ENGINE OIL PRESSURE 422
(B@BAZK) 423
ABNORMAL ENGINE OIL LEVEL 423
(B@BCNS) 424
ENGINE COOLANT INDICATING OVERHEAT CONDITION 424
(B@BCZK) 425
ABNORMAL COOLANT LEVEL INDICATION 425
(B@HANS) 426
HYDRAULIC OIL OVERHEAT INDICATION 426
TROUBLESHOOTING MONITOR ELECTRICAL SYSTEM (E MODE) 427
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 428
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF 428
USER CODE MEMORY RETENTION FUNCTION 428
INFORMATION CONTAINED IN TESTING PROCEDURES 429
(E-1) 431
ENGINE WILL NOT CRANK 431
(E-2) 433
ENGINE STOPS WHILE IN OPERATION 433
(E-3) 435
ENGINE SPEED IRREGULAR, OR HUNTING 435
(E-4) 437
ENGINE DOES NOT SHUT DOWN 437
(E-5) 439
AUTO DECELERATOR DOES NOT WORK 439
(E-6) 440
AUTO ENGINE WARM UP DEVICE DOES NOT WORK 440
(E-7) 441
COLD START PREHEATER DOES NOT WORK 441
(E-8) 443
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE 443
(E-9) 445
ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE 445
(E-10) 447
NO DISPLAY ON MONITOR PANEL 447
(E-11) 449
PART OF DISPLAY ON MONITOR PANEL IS MISSING 449
(E-12) 450
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL 450
(E-13) 451
FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL 451
(E-14) 453
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 453
(E-15) 455
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY 455
(E-16) 457
FUEL GAUGE DOES NOT DISPLAY CORRECTLY 457
(E-17) 459
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY 459
(E-18) 461
WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS 461
(E-19) 463
WINDSHIELD WIPER DOES NOT WORK 463
(E-20) 465
ALARM BUZZER CANNOT BE CANCELLED 465
(E-21) 467
BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR 467
(E-22) 469
BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR 469
(E-23) 471
ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR 471
(E-24) 473
ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR 473
(E-25) 475
BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR 475
(E-26) 477
BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR 477
(E-27) 479
SWING NOT CORRECTLY DISPLAYED ON MONITOR 479
(E-28) 481
TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR 481
(E-29) 483
TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR 483
(E-30) 485
SERVICE NOT CORRECTLY DISPLAYED ON MONITOR 485
(E-31) 487
AIR CONDITIONER SYSTEM DOES NOT WORK 487
(E-32) 491
TRAVEL ALARM DOES NOT SOUND 491
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 495
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 497
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 500
(H-1) 501
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW 501
(H-2) 502
ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS 502
(H-3) 503
NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT 503
(H-4) 503
ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP 503
(H-5) 504
AUTO-DECELERATOR DOES NOT WORK 504
(H-6) 504
FINE CONTROL MODE DOES NOT FUNCTION 504
(H-7) 505
BOOM MOVES SLOWLY OR LACKS POWER 505
(H-8) 506
ARM MOVES SLOWLY OR LACKS POWER 506
(H-9) 507
BUCKET MOVES SLOWLY OR LACKS POWER 507
(H-10) 508
WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION 508
(H-11) 509
WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT 509
(H-12) 510
WORK EQUIPMENT HAS EXCESSIVE LAG TIME 510
(H-13) 511
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT 511
(H-14) 511
ONE-TOUCH POWER MAX SWITCH DOES NOT OPERATE 511
(H-15) 511
IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY 511
(H-16) 512
IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY 512
(H-17) 512
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY 512
(H-18) 513
MACHINE SWERVES WHEN TRAVELING 513
(H-19) 514
MACHINE TRAVELS SLOWLY 514
(H-20) 515
MACHINE CANNOT BE STEERED EASILY OR LACKS POWER 515
(H-21) 516
TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING 516
(H-22) 516
TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY) 516
(H-23) 517
MACHINE DOES NOT SWING 517
(H-24) 518
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW 518
(H-25) 519
EXCESSIVE OVERRUN WHEN STOPPING SWING 519
(H-26) 520
THERE IS A SUDDEN SHOCK WHEN STOPPING SWING 520
(H-27) 520
ABNORMAL NOISE CAUSED WHEN STOPPING SWING 520
(H-28) 521
SWING NATURAL DRIFT IS EXCESSIVE 521
30 DISASSEMBLY AND ASSEMBLY 523
METHOD OF USING MANUAL 525
PRECAUTIONS DURING OPERATION 527
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 527
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 528
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 529
OTHER PRECAUTIONS 529
SPECIAL TOOL LIST 530
SKETCHES OF SPECIAL TOOLS 533
CONNECTOR REPAIR PROCEDURES 535
CONTACT TERMINAL REMOVAL (HD30 TYPE) 535
STRIPING INSULATION 536
CRIMPING CONTACT TERMINAL (HD30 TYPE) 537
INSERTION OF CONTACT TERMINAL (HD30 TYPE) 538
CONTACT TERMINAL REMOVAL (DT TYPE) 539
STRIPING INSULATION 540
CRIMPING CONTACT TERMINAL (DT TYPE) 541
INSERTION OF CONTACT TERMINAL (DT TYPE) 542
ENGINE 543
ALTERNATOR 543
CYLINDER HEAD 543
ENGINE FRONT SEAL 543
ENGINE OIL COOLER 543
ENGINE REAR SEAL 543
FUEL INJECTION PUMP 543
NOZZLE HOLDER 543
STARTING MOTOR 543
THERMOSTAT 543
TURBOCHARGER 543
WATER PUMP 543
RADIATOR 544
REMOVAL 544
INSTALLATION 545
HYDRAULIC OIL COOLER 546
REMOVAL 546
INSTALLATION 547
ENGINE AND HYDRAULIC PUMPS 548
REMOVAL 548
INSTALLATION 552
FINAL DRIVE 553
REMOVAL 553
INSTALLATION 553
DISASSEMBLY 554
ASSEMBLY 558
TRAVEL MOTOR 564
DISASSEMBLY 564
ASSEMBLY 568
SWING MOTOR 578
REMOVAL 578
INSTALLATION 578
DISASSEMBLY 579
ASSEMBLY 581
SWING MACHINERY 588
REMOVAL 588
INSTALLATION 588
DISASSEMBLY 589
ASSEMBLY 592
IDLER AND RECOIL SPRING 597
REMOVAL 597
INSTALLATION 597
IDLER 598
RECOIL SPRING 602
TRACK ROLLER 604
REMOVAL 604
INSTALLATION 604
DISASSEMBLY 605
ASSEMBLY 606
SPROCKET 609
REMOVAL 609
INSTALLATION 609
TRACK SHOE 610
EXPANSION OF TRACK SHOE 610
ASSEMBLY 611
SWING CIRCLE 612
REMOVAL 612
INSTALLATION 612
REVOLVING FRAME 613
REMOVAL 613
INSTALLATION 615
CENTER SWIVEL JOINT 616
REMOVAL 616
INSTALLATION 617
DISASSEMBLY 618
ASSEMBLY 618
HYDRAULIC TANK 619
REMOVAL 619
INSTALLATION 620
CONTROL VALVE 621
REMOVAL 621
INSTALLATION 623
REPLACING PRESSURE COMPENSATION VALVE SEAL 624
ASSEMBLY 625
HYDRAULIC PUMP 626
REMOVAL 626
INSTALLATION 628
INPUT SHAFT OIL SEAL 629
WORK EQUIPMENT PPC VALVE 630
ASSEMBLY 630
TRAVEL PPC VALVE 631
ASSEMBLY 631
HYDRAULIC CYLINDER 632
DISASSEMBLY 632
ASSEMBLY 634
WORK EQUIPMENT 638
REMOVAL 638
INSTALLATION 639
AIR CONDITIONER 641
REMOVAL 641
INSTALLATION 644
COUNTERWEIGHT 645
REMOVAL 645
INSTALLATION 645
OPERATOR’S CAB 646
REMOVAL 646
INSTALLATION 648
MONITOR 649
REMOVAL 649
INSTALLATION 649
GOVERNOR PUMP CONTROLLER 650
REMOVAL 650
INSTALLATION 650
90 OTHERS 651
ELECTRICAL 653
ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 3) FOLDOUT 1 653
ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 3) FOLDOUT 2 655
ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 3) FOLDOUT 3 657
ELECTRICAL DIAGRAM 2/4 (SHEET 1 OF 1) FOLDOUT 4 659
ELECTRICAL DIAGRAM 3/4 (SHEET 1 OF 2) FOLDOUT 5 661
ELECTRICAL DIAGRAM 3/4 (SHEET 2 OF 2) FOLDOUT 6 663
ELECTRICAL DIAGRAM 4/4 (SHEET 1 OF 2) FOLDOUT 7 665
ELECTRICAL DIAGRAM 4/4 (SHEET 2 OF 2) FOLDOUT 8 667
HYDRAULIC 669
HYDRAULIC DIAGRAM (SHEET 1 OF 3) FOLDOUT 9 669
HYDRAULIC DIAGRAM (SHEET 2 OF 3) FOLDOUT 10 671
HYDRAULIC DIAGRAM (SHEET 3 OF 3) FOLDOUT 11 673
S.V 11/12/24
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