Komatsu PC300-5 Custom PC400-5 Custom Excavator Shop Manual SEBM0207C503 PDF
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Komatsu PC300-5 Custom PC400-5 Custom Excavator Shop Manual SEBM0207C503 – PDF DOWNLOAD
MACHINE MODEL SERIAL NO.
РСЗ00-5 20001 and up
РС400-5 20001 and up
Description
Komatsu PC300-5 Custom PC400-5 Custom Excavator Shop Manual SEBM0207C503 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC300-5 Custom PC400-5 Custom Excavator Shop Manual SEBM0207C503 – PDF DOWNLOAD
Language : English
Pages : 525
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC300-5 Custom PC400-5 Custom Excavator Shop Manual SEBM0207C503 – PDF DOWNLOAD
MACHINE MODEL SERIAL NO.
РСЗ00-5 20001 and up
РС400-5 20001 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 PC300-5 Custom PC400-5 Custom Excavator Shop Manual SEBM0207C503 – PDF DOWNLOAD
MACHINE MODEL SERIAL NO.
РСЗ00-5 20001 and up
РС400-5 20001 and up
COVER 1
CONTENTS 2
10 STRUCTURE AND FUNCTION 24
POWER TRAIN 25
FINAL DRIVE 26
SWING CIRCLE 28
SWING MACHINERY 30
TRACK FRAME AND RECOIL SPRING 32
IDLER 34
TRACK ROLLER, CARRIER ROLLER 36
TRACK SHOE 37
HYDRAULIC PIPING 40
HYDRAULIC CIRCUIT DIAGRAM 42
HYDRAULIC TANK 45
HYDRAULIC PUMP 47
CONTROL VALVE 63
SWING MOTOR 80
CENTER SWIVEL JOINT 83
TRAVEL MOTOR 84
VALVE CONTROL 93
PPC VALVE 95
ACCUMULATOR, SAFETY LOCK VALVE 101
SOLENOID VALVE ASSEMBLY 102
SHUTTLE VALVE 105
HYDRAULIC CYLINDER 106
ELECTRICAL WIRING DIAGRAM 112
ELECTRICAL CIRCUIT DIAGRAM 116
ENGINE CONTROL SYSTEM 124
GOVERNOR MOTOR LINKAGE 125
OLSS SYSTEM 135
EMACC 141
20 TESTING AND ADJUSTING 149
TABLE OF JUDGEMENT STANDARD VALUE 150
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 170
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 175
ADJUSTING VALVE CLEARANCE 176
MEASURING COMPRESSION PRESSURE 178
TESTING AND ADJUSTING FUEL INJECTION TIMING 179
TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER 181
ADJUSTING FUEL CONTROL LEVER 182
INSPECTION OF SWING CIRCLE BEARING CLEARANCE 183
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 184
TESTING AND ADJUSTING CHARGING PUMP PRESSURE 186
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE 188
TESTING AND ADJUSTING TRAVEL DEVIATION 195
MEASURING OUTPUT PRESSURE OF PPC VALVE 197
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 198
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE 199
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 200
BLEEDING AIR 201
TROUBLESHOOTING 204
POINTS TO REMEMBER WHEN TROUBLESHOOTING 205
SEQUENCE OF EVENTS IN TROUBLESHOOTING 206
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 207
HANDLING CONNECTORS 214
CHECKS BEFORE TROUBLESHOOTING 215
ELECTRICAL CIRCUIT DIAGRAM 216
POSITION OF CONNECTORS FOR TROUBLESHOOTING 220
CONNECTION TABLE FOR CONNECTOR 224
DISPLAY METHOD FOR MONITOR PANEL AND ENGINE THROTTLE CONTROLLER 232
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE 233
METHOD OF USING JUDGEMENT TABLE 234
METHOD OF USING TROUBLESHOOTING CHARTS 235
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE) 237
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS 238
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM 239
E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF) 240
E-2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAYED 242
E-3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED 243
E-4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED 244
E-5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED 245
E-6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED 246
E-7 ENGINE DOES NOT START 247
E-8 ENGINE ROTATION IS IRREGULAR 249
a) IDLING ROTATION IS IRREGULAR 249
b) THERE IS HUNTING 251
E-9 LACK OF OUTPUT POWER (MAX ENGINE SPEED IS TOO LOW) 253
E-10 ENGINE DOES NOT STOP 255
E-11 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE 257
TROUBLESHOOTING OF SOLENOID CIRCUIT (C MODE) 258
C-1 ACTUATION OF TVC SOLENOID IS DEFECTIVE 259
C-2 DOES NOT SWING (STAYS LOCKED) 260
C-3 SWING IS NOT LOCKED (REMAINS FREE) 261
C-4 TRAVEL SPEED STAYS AT LO (DOES NOT SWITCH TO HI) 262
C-5 TRAVEL SPEED STAYS AT HI (DOES NOT SWITCH TO LO) 263
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 264
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL, SWING ARE ALL SLOW 265
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 267
H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW 269
H-4 WORK EQUIPMENT, TRAVEL, SWING LACK POWER 271
H-5 ABNORMAL NOISE GENERATED (FROM AROUND PUMP) 271
H-6 BOOM, ARM SPEED IS EXTREMELY SLOW 272
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW 272
H-8 WHEN BOOM AND ARM ARE OPERATED SIMULTANEOUSLY, BOOM IS SLOW 273
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER 273
H-10 EXCESSIVE HYDRAULIC DRIFT 273
H-11 EXCESSIVE TIME LAG 274
H-12 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY, ARM IS SLOW 274
H-13 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE 275
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE 275
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE 277
H-14 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS 278
H-15 EXCESSIVE DEVIATION WHEN STARTING 279
H-16 TRAVEL LACKS POWER (OR SPEED IS SLOW) 281
H-17 TRAVEL SPEED DOES NOT SWITCH 281
H-18 MACHINE DOES NOT MOVE (ONE SIDE ONLY) 282
H-19 DOES NOT SWING 283
H-20 SWING SPEED IS SLOW OR ACCELERATION IS POOR 285
H-21 EXCESSIVE OVERRUN WHEN STOPPING SWING 286
H-22 EXCESSIVE SHOCK WHEN STOPPING SWING 286
H-23 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 287
H-24 EXCESSIVE HYDRAULIC DRIFT OF SWING 287
H-25 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW 287
TABLE OF FAILURE MODES AND CAUSES 288
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE) 289
P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON 290
a) NO MONITOR PANEL LAMPS LIGHT UP 290
b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP 290
P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT 291
P-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 292
a) COOLANT LEVEL FLASHES 292
P-4 PREHEATING IS NOT BEING USED, BUT PREHEATING DISPLAY FLASHES 293
P-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH 295
a) ALTERNATOR SYSTEM 295
b) ENGINE OIL PRESSURE SYSTEM 295
P-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH 296
P-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH 297
a) ENGINE OIL PRESSURE FLASHES 297
b) COOLANT LEVEL FLASHES 297
c) COOLANT TEMPERATURE FLASHES 298
d) CHARGE FLASHES 298
e) FUEL LEVEL FLASHES 299
P-8 ABNORMALITY IN BUZZER CIRCUIT 300
a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND 300
b) CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND 300
c) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS 300
P-9 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP 301
P-10 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE 302
P-11 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY 302
P-12 FUEL GAUGE ALWAYS DISPLAYS FULL 303
P-13 FUEL GAUGE GIVES NO DISPLAY 303
P-14 ABNORMALITY IN LAMP CIRCUIT 304
a) LAMPS DO NOT LIGHT UP 304
b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NOT OPERATED 304
P-15 ABNORMALITY IN WIPER CIRCUIT 306
a) WIPERS DO NOT WORK 306
b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED 306
P-16 ABNORMALITY IN FAN CIRCUIT 308
a) FAN DOES NOT WORK 308
b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED 308
P-17 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 30℃, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30℃ 310
P-18 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP 311
P-19 FUEL LEVEL SENSOR SYSTEM DEFECTIVE 312
P-20 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE 313
P-21 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE 314
30 DISASSEMBLY AND ASSEMBLY 315
METHOD OF USING MANUAL 317
PRECAUTIONS WHEN CARRYING OUT OPERATION 318
SPECIAL TOOL LIST 320
WEIGHT TABLE 322
TIGHTENING TORQUES AND STANDARD VALUES TABLE 323
LUBRICANT AND COOLANT TABLE 329
STARTING MOTOR 330
REMOVAL AND INSTALLATION 330
ALTERNATOR 330
REMOVAL AND INSTALLATION 330
ENGINE OIL COOLER 332
REMOVAL AND INSTALLATION 332
FUEL INJECTION PUMP 334
REMOVAL AND INSTALLATION 334
WATER PUMP 336
REMOVAL AND INSTALLATION 336
NOZZLE HOLDER 338
REMOVAL AND INSTALLATION 338
TURBOCHARGER 340
REMOVAL AND INSTALLATION 340
THERMOSTAT 340
REMOVAL AND INSTALLATION 340
ENGINE FRONT OIL SEAL 342
REMOVAL AND INSTALLATION 342
ENGINE REAR OIL SEAL 344
REMOVAL AND INSTALLATION 344
GOVERNOR MOTOR 346
REMOVAL AND INSTALLATION 346
CYLINDER HEAD 348
REMOVAL AND INSTALLATION (PC300) 348
REMOVAL AND INSTALLATION (PC400) 350
AFTERCOOLER CORE 352
REMOVAL AND INSTALLATION (PC300) 352
HYDRAULIC COOLER 354
REMOVAL AND INSTALLATION 354
RADIATOR, HYDRAULIC OIL COOLER 356
REMOVAL AND INSTALLATION 356
ENGINE, HYDRAULIC PUMP 358
REMOVAL AND INSTALLATION (PC300) 358
REMOVAL (PC400) 360
INSTALLATION (PC400) 362
DAMPER 362
REMOVAL AND INSTALLATION 362
CENTER SWIVEL JOINT 364
REMOVAL AND INSTALLATION 364
DISASSEMBLY AND ASSEMBLY 364
FINAL DRIVE 366
REMOVAL AND INSTALLATION 366
DISASSEMBLY 366
ASSEMBLY 370
SPROCKET 376
REMOVAL AND INSTALLATION 376
SWING MOTOR 376
REMOVAL AND INSTALLATION 376
SWING MACHINERY 378
REMOVAL AND INSTALLATION 378
DISASSEMBLY 380
ASSEMBLY 382
REVOLVING FRAME 388
REMOVAL AND INSTALLATION 388
SWING CIRCLE 390
REMOVAL AND INSTALLATION 390
IDLER, RECOIL SPRING 390
REMOVAL AND INSTALLATION 390
RECOIL SPRING 392
DISASSEMBLY AND ASSEMBLY 392
TRACK ROLLER 394
REMOVAL AND INSTALLATION 394
CARRIER ROLLER 394
REMOVAL AND INSTALLATION 394
TRACK SHOE 396
REMOVAL AND INSTALLATION 396
CHARGING PUMP 396
REMOVAL AND INSTALLATION 396
HYDRAULIC PUMP 398
REMOVAL AND INSTALLATION 398
HYDRAULIC PUMP INPUT SHAFT OIL SEAL 400
REMOVAL AND INSTALLATION 400
CONTROL VALVE 402
REMOVAL AND INSTALLATION 402
DISASSEMBLY 404
ASSEMBLY 406
MAIN RELIEF VALVE 408
REMOVAL AND INSTALLATION 408
DISASSEMBLY AND ASSEMBLY 408
TVC VALVE 410
REMOVAL AND INSTALLATION 410
CO・NC VALVE 410
REMOVAL AND INSTALLATION 410
SERVO VALVE 410
REMOVAL AND INSTALLATION 410
WORK EQUIPMENT PPC VALVE 412
REMOVAL AND INSTALLATION 412
DISASSEMBLY AND ASSEMBLY 412
TRAVEL PPC VALVE 414
REMOVAL AND INSTALLATION 414
DISASSEMBLY AND ASSEMBLY 414
PPC SHUTTLE VALVE 416
REMOVAL AND INSTALLATION 416
BOOM CYLINDER 418
PC300-5, PC400-5 (BACK HOE) 418
REMOVAL AND INSTALLATION 418
ARM CYLINDER 420
PC300-5, PC400-5 (BACK HOE) 420
REMOVAL AND INSTALLATION 420
BUCKET CYLINDER 422
PC300-5, PC400-5 (BACK HOE) 422
REMOVAL AND INSTALLATION 422
BOOM CYLINDER 424
PC400-5 (LOADING SHOVEL) 424
REMOVAL AND INSTALLATION 424
ARM CYLINDER 426
PC400-5 (LOADING SHOVEL) 426
REMOVAL AND INSTALLATION 426
BUCKET CYLINDER 428
PC400-5 (LOADING SHOVEL) 428
REMOVAL AND INSTALLATION 428
BOTTOM DUMP CYLINDER 430
PC400-5 (LOADING SHOVEL) 430
REMOVAL AND INSTALLATION 430
HYDRAULIC CYLINDER 432
DISASSEMBLY 432
ASSEMBLY 434
WORK EQUIPMENT 436
PC300-5, PC400-5 (BACK HOE) 436
REMOVAL AND INSTALLATION 436
BUCKET 438
PC300-5, PC400-5 (BACK HOE) 438
REMOVAL AND INSTALLATION 438
ARM 438
PC300-5, PC400-5 (BACK HOE) 438
REMOVAL AND INSTALLATION 438
ARM, BUCKET 440
PC300-5, PC400-5 (BACK HOE) 440
REMOVAL AND INSTALLATION 440
BOOM 442
PC300-5, PC400-5 (BACK HOE) 442
REMOVAL AND INSTALLATION 442
WORK EQUIPMENT 444
PC400-5 (LOADING SHOVEL) 444
REMOVAL AND INSTALLATION 444
BOOM 446
PC400-5 (LOADING SHOVEL) 446
REMOVAL AND INSTALLATION 446
ARM 448
PC400-5 (LOADING SHOVEL) 448
REMOVAL AND INSTALLATION 448
BUCKET 450
PC400-5 (LOADING SHOVEL) 450
REMOVAL AND INSTALLATION 450
OPERATOR’S CAB 452
REMOVAL AND INSTALLATION 452
COUNTER WEIGHT 452
REMOVAL AND INSTALLATION 452
ENGINE THROTTLE CONTROLLER 454
REMOVAL AND INSTALLATION 454
MONITOR PANEL 454
REMOVAL AND INSTALLATION 454
PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT 456
PC300 456
PC400 464
40 MAINTENANCE STANDARD 472
FINAL DRIVE 473
SWING CIRCLE 477
SWING MACHINERY 479
TRACK FRAME AND RECOIL SPRING 483
IDLER 485
TRACK ROLLER 489
CARRIER ROLLER 491
TRACK SHOE 492
HYDRAULIC PUMP 496
CHARGING PUMP AND RELIEF VALVE 497
CONTROL VALVE 498
TRAVEL SHUTTLE VALVE 512
SWING MOTOR 513
CENTER SWIVEL JOINT 514
TRAVEL MOTOR 515
PPC VALVE 517
PPC SHUTTLE VALVE 519
HYDRAULIC CYLINDER 520
WORK EQUIPMENT 522
S.V 18/12/24
