Komatsu HYDRAULIC EXCAVATOR PC300 -8 PC300LC-8 Shop Manual SEN01983-15TH – PDF DOWNLOAD

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.

2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc.

4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.

5) Only qualified workers must carry out work and operation which require license or qualification.

6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.

8) Before starting work, warm up your body thoroughly to start work under good condition.

9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines 34
How to read electric wire code 37
Precautions when carrying out operation 40
Method of disassembling and connecting push-pull type coupler 43
Standard tightening torque table 46
Conversion table 50
01 Specification 57
Specification and technical data 57
Specification dimension drawings 58
Dimensions 58
Working ranges 59
Specifications 60
Weight table 66
Table of fuel, coolant and lubricants 68
10 Structure, function and maintenance standard 71
Engine and cooling system 71
Engine related parts 72
Radiator, oil cooler and aftercooler 73
Engine and cooling system 71
Power train 76
Swing circle 77
Swing machinery 78
Final drive 80
Sprocket 82
Undercarriage and frame 85
Track frame and recoil spring 86
Idler 88
Carrier roller 90
Track roller 91
Track shoe 92
Hydraulic system, Part 1 97
Hydraulic equipment layoutdrawing 98
Hydraulic tank and filter 100
Hydraulic pump 102
Hydraulic system, Part 2 127
Control valve 128
CLSS 140
Functions and operation by valve 144
Merge-divider valve 159
Attachment circuit selector valve 184
Hydraulic drift prevention valve 1 186
Hydraulic system, Part 3 193
Valve control 194
PPC valve 196
Solenoid valve 218
PPC accumulator 220
Return oil filter 221
Center swivel joint 222
Travel motor 223
Swing motor 235
Hydraulic cylinder 244
Work equipment 247
Work equipment 248
Dimensions of components 250
Cab and its attachments 255
Air conditioner piping 256
Electrical system 259
Engine control 260
Electronic control system 269
Monitor system 294
Sensor 321
KOMTRAX system 324
20 Standard value table 327
Standard service value table 327
Standard value table for engine related parts 328
Standard value table for chassis related parts 329
30 Testing and adjusting 341
Testing and adjusting, Part 1 341
Tools for testing, adjusting and troubleshooting 343
Sketches of special tools 347
Testing engine speed 348
Testing air boost pressure 349
Testing exhaust gas color 350
Adjusting valve clearance 352
Testing compression pressure 354
Testing blow-by pressure 358
Testing engine oil pressure 359
Testing fuel pressure 360
Handling during cylinder cut-outoperation 365
Handling during no injectioncranking operation 365
Testing fuel return rate andleakage 366
Bleeding air from fuel circuit 368
Checking fuel circuit for leakage 369
Testing and adjusting aircompressor belt tension 370
Replacing fan belt 371
Replacing alternator belt 372
Testing clearance in swing circlebearings 373
Testing and adjusting track shoetension 374
Testing and adjusting oil pressurein work equipment, swing andtravel circuit 375
Testing and adjusting controlcircuit oil pressure 379
Testing and adjusting pump PCcontrol circuit oil pressure 380
Testing and adjusting pump LScontrol circuit oil pressure 383
Testing solenoid valve outputpressure 388
Testing PPC valve output pressure 392
Adjusting play of work equipmentand swing PPC valves 393
Inspecting locations of hydraulicdrift of work equipment 394
Releasing remaining pressure inhydraulic circuit 396
Testing oil leakage amount 396
Bleeding air from various parts 399
Diode inspection procedures 401
Testing and adjusting, Part 2 407
Special functions of machine monitor 408
Testing and adjusting, Part 3 465
Handling voltage circuit of enginecontroller 466
Preparation work fortroubleshooting of electricalsystem 467
Procedure for testing diodes 471
Pm clinic service 472
40 Troubleshooting 479
Failure code table and fuse locations 479
Failure codes table 480
Fuse locations 483
General Information on troubleshooting 489
Points to remember when troubleshooting 490
Sequence of events in troubleshooting 491
Checks before troubleshooting 492
Classification and troubleshooting steps 493
Information in troubleshooting table 494
Possible problems and troubleshooting No 496
Connection table for connector pin numbers 499
T- branch box and T- branch adapter table 535
Troubleshooting by failure code(Display of code), Part 1 539
Failure code [989L00] Engine Controller Lock Caution 1 541
Failure code [989N00] Engine Controller Lock Caution 3 542
Failure code [AA10NX] Air cleaner Clogging 544
Failure code [AB00KE] Charge Voltage Low 546
Failure code [B@BAZG] Eng Oil Press Low 548
Failure code [B@BAZK] Eng Oil Level Low 550
Failure code [B@BCNS] Eng Water Overheat 552
Failure code [B@BCZK] Eng Water Level Low 554
Failure code [B@HANS] Hydr Oil Overheat 556
Failure code [CA111] EMC Critical Internal Failure 557
Failure code [CA122] Chg Air Press Sensor High Error 558
Failure code [CA123] Chg Air Press Sensor Low Error 560
Failure code [CA131] Throttle Sensor High Error 562
Failure code [CA132] Throttle Sensor Low Error 564
Failure code [CA144] Coolant Temp Sens High Error 566
Failure code [CA145] Coolant Temp Sens Low Error 568
Failure code [CA153] Chg Air Temp Sensor High Error 570
Failure code [CA154] Chg Air Temp Sensor Low Error 572
Failure code [CA155] Chg Air Temp High Speed Derate 574
Failure code [CA187] Sens Supply 2 Volt Low Error 576
Failure code [CA221] Ambient Press Sens High Error 578
Failure code [CA222] Ambient Press Sens Low Error 580
Failure code [CA227] Sens Supply 2 Volt High Error 582
Failure code [CA234] Eng Overspeed 583
Failure code [CA238] Ne Speed Sens Supply Volt Error 584
Failure code [CA271] IMV/PCV1 Short Error 585
Failure code [CA272] IMV/PCV1 Open Error 586
Failure code [CA281] Pump Press Balance Error 588
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error 589
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error 591
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error 593
Failure code [CA325] Inj #6 (L/B#6) Open/Short Error 595
Failure code [CA331] Inj #2 (L/B#2) Open/Short Error 597
Failure code [CA332] Inj #4 (L/B#4) Open/Short Error 599
Troubleshooting by failure code(Display of code), Part 2 603
Failure code [CA342] Calibration Code Incompatibility 605
Failure code [CA351] Injectors Drive Circuit Error 606
Failure code [CA352] Sens Supply 1 Volt Low Error 608
Failure code [CA386] Sens Supply 1 Volt High Error 610
Failure code [CA428] Water in Fuel Sensor High Error 612
Failure code [CA429] Water in Fuel Sensor Low Error 614
Failure code [CA435] Eng Oil Press Sw Error 616
Failure code [CA441] Battery Voltage Low Error 618
Failure code [CA442] Battery Voltage High Error 620
Failure code [CA449] Rail Press Very High Error 622
Failure code [CA451] Rail Press Sensor High Error 626
Failure code [CA452] Rail Press Sensor Low Error 628
Failure code [CA488] Chg Air Temp High Torque Derate 630
Failure code [CA559] Rail Press Low Error 632
Failure code [CA689] Eng Ne Speed Sensor Error 634
Failure code [CA731] Eng Bkup Speed Sens Phase Error 636
Failure code [CA757] All Persistent Data Lost Error 638
Failure code [CA778] Eng Bkup Speed Sensor Error 640
Failure code [CA1633] KOMNET Datalink Timeout Error 642
Failure code [CA2185] Throt Sens Sup Volt High Error 644
Failure code [CA2186] Throt Sens Sup Volt Low Error 645
Failure code [CA2249] Rail Press Very Low Error 646
Failure code [CA2265] Fuel Feed Pump Open Error 648
Failure code [CA2266] Fuel Feed Pump Short Error 650
Failure code [CA2311] IMV Solenoid Error 652
Failure code [CA2555] Grid Htr Relay Volt Low Error 654
Failure code [CA2556] Grid Htr Relay Volt High Error 656
Failure code [D110KB] Battery Relay Drive S/C 658
Failure code [D19JKZ] Personal Code Relay Abnormal 660
Failure code [D862KA] GPS Antenna Discon 662
Failure code [DA22KK] Pump Solenoid Power Low Error 663
Failure code [DA25KP] 5V sensor 1 power abnormality 665
Failure code [DA29KQ] Model Selection Abnormality 668
Failure code [DA2RMC] Pump Comm Abnormality 670
Failure code [DAF8KB] Short circuit in camera power supply 672
Failure code [DAFGMC] GPS Module Error 674
Troubleshooting by failure code(Display of code), Part 3 677
Failure code [DAFRMC] CAN discon (Monitor detected) 680
Failure code [DGH2KB] Hydr Oil Sensor Short 682
Failure code [DHPAMA] F Pump Press Sensor Abnormality 684
Failure code [DHPBMA] R Pump Press Sensor Abnormality 686
Failure code [DHS3MA] Arm Curl PPC Sensor Abnormality 688
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 690
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) 692
Failure code [DW43KA] Travel Speed Sol Open Circuit 694
Failure code [DW43KB] Travel Speed Sol Short Circuit 696
Failure code [DW45KA] Swing Brake Sol Open Circuit 698
Failure code [DW45KB] Swing Brake Sol Short Circuit 702
Failure code [DW91KA] Travel Junction Sol Open Circuit 704
Failure code [DW91KB] Travel Junction Sol Short Circuit 706
Failure code [DWA2KA] Attachment Sol Open Circuit 708
Failure code [DWA2KB] Attachment Sol Short Circuit 709
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 710
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 712
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 714
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 716
Failure code [DXA0KA] PC-EPC Sol Open Circuit 718
Failure code [DXA0KB] PC-EPC Sol Short Circuit 720
Failure code [DXE0KA] LS-EPC Sol Open Circuit 722
Failure code [DXE0KB] LS-EPC Sol Short Circuit 724
Failure code [DXE4KA] Service Current EPC Open Circuit 726
Failure code [DXE4KB] Service Current EPC Short Circuit 727
Failure code [DY20KA] Wiper Working Abnormality 728
Failure code [DY20MA] Wiper Parking Abnormality 730
Failure code [DY2CKA] Washer Drive Open Circuit 732
Failure code [DY2CKB] Washer Drive Short Circuit 734
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 736
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 738
Troubleshooting of electrical system(E-mode) 741
Before carrying out troubleshooting of electrical system 744
Information contained in troubleshooting table 746
E-1 Engine does not start 747
E-2 Auto-decelerator does not operate 750
E-3 Automatic warming-up system does not operate 752
E-4 Preheater does not operate 754
E-5 All work equipment, swing, and travel mechanism do not move 756
E-6 Power maximizing function does not operate 758
E-7 Machine monitor does not display at all 760
E-8 Machine monitor does not display some items 762
E-10 Fuel level monitor was lighted in red while engine running 763
E-11 Engine coolant temperature gauge does not indicate normally 764
E-12 Hydraulic oil temperature gauge does not indicate normally 766
E-13 Fuel level gauge does not indicate normally 767
E-14 Swing lock monitor does not indicate normally 768
E-15 When monitor switch is operated, monitor displays nothing 770
E-16 Windshield wiper and window washer do not operate 772
E-17 Machine push-up function does not operate normally 776
E-18 Monitoring function fails to display “boom raise” normally 778
E-19 Monitoring function fails to display “boom lower” normally 780
E-20 Monitoring function fails to display “arm IN” normally 782
E-21 Monitoring function fails to display “arm OUT” normally 784
E-22 Monitoring function fails to display “bucket CURL” normally 786
E-23 Monitoring function fails to display “bucket DUMP” normally 788
E-24 Monitoring function fails to display “swing” normally 790
E-25 Monitoring function fails to display “travel” normally 792
E-26 Monitoring function fails to display “travel differential pressure”normally 794
E-27 Monitoring function fails to display “service” normally 796
E-28 KOMTRAX system does not operate normally 798
E-29 Air conditioner does not operate 800
E-30 Travel alarm does not sound or does not stop sounding 802
E-31 Horn does not sound 804
Troubleshooting of hydraulic andmechanical system (H-mode) 807
System chart for hydraulic and mechanical system 810
Information contained in troubleshooting table 812
H-1 All work equipment lack power, or travel and swing speeds areslow 814
H-2 Engine speed sharply drops or engine stalls 816
H-3 No work equipment, swing or travel move 817
H-4 Abnormal noise is heard from around hydraulic pump 817
H-5 Auto-decelerator does not work 818
H-6 Fine control mode does not function or responds slow 818
H-7 Boom moves slowly or lacks power 819
H-8 Arm moves slowly or lacks power 820
H-9 Bucket moves slowly or lacks power 821
H-10 Work equipment does not move in its single operation 821
H-11 Work equipment has a bit too fast hydraulic drift 822
H-12 Work equipment has big time lag 824
H-13 Other work equipment moves when relieving single circuit 824
H-14 Power max switch does not operate 825
H-15 In compound operation, work equipment with larger load movesslowly 825
H-16 In swing + boom RAISE operation, boom moves slowly 826
H-17 In swing + travel operation, travel speed drops sharply 826
H-18 Machine swerves in travel 827
H-19 Machine travels slowly 828
H-20 Machine cannot be easily steered or lacks power 829
H-21 Travel speed does not shift, or it is too slow or fast 830
H-22 Track shoe does not turn (on one side only) 831
H-23 Machine does not swing 832
H-24 Swing acceleration is poor, or swing speed is slow 834
H-25 Excessive overrun when stopping swing 836
H-26 There is big shock when stopping swing 837
H-27 Large sound is made when upper structure stops swinging 837
H-28 Swing hydraulic drift is too big 838
Troubleshooting of engine (S-mode) 841
Method of using troubleshooting chart 843
S-1 Starting performance is poor1 846
S-2 Engine does not start 847
S-3 Engine does not pick up smoothly 850
S-4 Engine stops during operations 851
S-5 Engine does not rotate smoothly 852
S-6 Engine lacks output (or lacks power) 853
S-7 Exhaust smoke is black (incomplete combustion) 854
S-8 Oil consumption is excessive (or exhaust smoke is blue) 855
S-9 Oil becomes contaminated quickly 856
S-10 Fuel consumption is excessive 857
S-11 Oil is in coolant(or coolant spurts back or coolant level goes down) 858
S-12 Oil pressure drops 859
S-13 Oil level rises (Entry of coolant or fuel) 860
S-14 Coolant temperature becomes too high (overheating) 861
S-15 Abnormal noise is made 862
S-16 Vibration is excessive 863
50 Disassembly and assembly 865
General information on disassembly andassembly 865
How to read this manual 866
Coating materials list 868
Special tool list 871
Sketches of special tools 874
Engine and cooling system 879
Removal and installation of fuelsupply pump assembly 880
Removal and installation ofengine front seal 883
Removal and installation ofengine rear seal 886
Removal and installation ofcylinder head assembly 891
Removal and installation ofradiator assembly 904
Removal and installation ofhydraulic oil cooler assembly 906
Removal and installation ofaftercooler assembly 908
Removal and installation ofengine and hydraulic pumpassembly 909
Power train 915
Removal and installation of finaldrive assembly 916
Disassembly and assembly offinal drive assembly 917
Removal and installation of swingmotor and swing machinery assembly 925
Disassembly and assembly ofswing motor and swing machineryassembly 926
Removal and installation of swingcircle assembly 933
Undercarriage and frame 935
Disassembly and assembly ofcarrier roller 936
Disassembly and assembly oftrack roller assembly 937
Disassembly and assembly ofidler assembly 938
Disassembly and assembly ofrecoil spring 941
Removal and installation ofsprocket 943
Expansion and installation oftrack shoe assembly 944
Removal and installation ofrevolving frame assembly 946
Removal and installation of counterweightassembly 948
Hydraulic system 953
Removal and installation of centerswivel joint assembly 954
Disassembly and assembly ofcenter swivel joint assembly 956
Removal and installation ofhydraulic tank assembly 957
Removal and installation ofcontrol valve assembly 959
Disassembly and assembly ofcontrol valve assembly 962
Removal and installation ofhydraulic pump assembly 963
Removal and installation of oil sealin hydraulic pump input shaft 965
Disassembly and assembly of work equipment PPC valve assembly 966
Disassembly and assembly oftravel PPC valve assembly 968
Disassembly and assembly ofhydraulic cylinder assembly 971
Work equipment 977
Removal and installation of workequipment assembly 978
Cab and its attachments 983
Removal and installation ofoperator’s cab assembly 984
Removal and installation of operator cab glass (stuck glass) 987
Removal and installation of frontwindow assembly 997
Removal and installation of floorframe assembly1004
Electrical system1009
Removal and installation of airconditioner unit assembly1010
Removal and installation ofKOMTRAX communicationmodem assembly1013
Removal and installation ofmonitor assembly1014
Removal and installation of pumpcontroller assembly1016
Removal and installation ofengine controller1018
90 Diagrams and drawings1021
Hydraulic diagrams and drawings1021
Hydraulic circuit diagram1023
Electrical diagrams and drawings1026
Electrical circuit diagram1028
Connector list and sterogram1033