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Komatsu PC300-5, PC300HD, PC400HD-5 Service Shop Repair Manual – PDF DOWNLOAD
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Description
Komatsu PC300-5, PC300HD, PC400HD-5 Service Shop Repair Manual
FILE DETAILS:
Komatsu PC300-5, PC300HD, PC400HD-5 Service Shop Repair Manual
Language : English
Pages : 748
Downloadable : Yes
File Type : PDF
Size: 48.9 MB
KOMATSU PC300-5, PC300HD, PC400HD-5 SERVICE SHOP REPAIR MANUAL – PDF DOWNLOAD:
DESCRIPTION:
Komatsu PC300-5, PC300HD, PC400HD-5 Service Shop Repair Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC300-5, PC300HD, PC400HD-5 Service Shop Repair Manual
MAIN MENU....................................................................................................................................... 0 SAFETY.......................................................................................................................................... 3 FOREWORD........................................................................................................................................ 5 HOW TO READ THE SHOP MANUAL................................................................................................................. 6 HOISTING INSTRUCTIONS....................................................................................................................... 7 STANDARD TIGHTENING TORQUE.................................................................................................................. 8 COATING MATERIALS........................................................................................................................... 9 ELECTRIC WIRE CODE.......................................................................................................................... 10 CONVERSION TABLE............................................................................................................................ 11 WEIGHT TABLE................................................................................................................................ 18 LIST OF LUBRICANT AND WATER................................................................................................................. 32 10 STRUCTURE AND FUNCTION....................................................................................................................... 35 POWER TRAIN................................................................................................................................. 36 FINAL DRIVE................................................................................................................................. 38 SWING CIRCLE................................................................................................................................ 40 SWING MACHINERY............................................................................................................................. 42 TRACK FRAME AND RECOIL SPRING............................................................................................................... 44 IDLER....................................................................................................................................... 50 TRACK ROLLER................................................................................................................................ 52 CARRIER ROLLER.............................................................................................................................. 52 TRACK SHOE.................................................................................................................................. 53 HYDRAULIC PIPING............................................................................................................................ 57 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................... 58 HYDRAULIC TANK.............................................................................................................................. 63 OLSS (Open center Load Sensing System)...................................................................................................... 65 HYDRAULIC PUMP.............................................................................................................................. 67 LINE OIL FILTER............................................................................................................................. 86 CONTROL VALVE............................................................................................................................... 88 SWING MOTOR.................................................................................................................................106 CENTER SWIVEL JOINT.........................................................................................................................109 TRAVEL MOTOR................................................................................................................................110 VALVE CONTROL...............................................................................................................................119 PPC VALVE...................................................................................................................................122 ACCUMULATOR.................................................................................................................................128 SAFETY LOCK VALVE...........................................................................................................................128 SOLENOID VALVE ASSEMBLY.....................................................................................................................129 SHUTTLE VALVE...............................................................................................................................133 BOOM HOLDING VALVE..........................................................................................................................134 HYDRAULIC CYLINDER..........................................................................................................................137 WORK EQUIPMENT..............................................................................................................................140 ELECTRICAL WIRING DIAGRAM...................................................................................................................146 ELECTRICAL CIRCUIT DIAGRAM..................................................................................................................150 ENGINE CONTROL SYSTEM.......................................................................................................................160 PEMC SYSTEM.................................................................................................................................173 EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)..............................................................................................202 20 TESTING AND ADJUSTING........................................................................................................................211 TABLE OF JUDGEMENT STANDARD VALUE...........................................................................................................212 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM..................................................................................................241 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...........................................................................................253 ADJUSTING VALVE CLEARANCE...................................................................................................................254 MEASURING COMPRESSION PRESSURE..............................................................................................................256 TESTING AND ADJUSTING FUEL INJECTION TIMING.................................................................................................257 TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER........................................................................................259 ADJUSTING ENGINE SPEED SENSOR...............................................................................................................260 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...........................................................263 TESTING AND ADJUSTING CHARGING PUMP PRESSURE................................................................................................266 TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE............................................................................................268 TESTING AND ADJUSTING TRAVEL DEVIATION......................................................................................................276 MEASURING STROKE OF SERVO PISTON............................................................................................................278 MEASURING OUTPUT PRESSURE OF PPC VALVE......................................................................................................279 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...................................................................................................280 TESTING PPC SHUTTLE VALVE...................................................................................................................281 MEASURING SOLENOID VALVE OUTLET PORT PRESSURE...............................................................................................282 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.................................................................................283 BLEEDING AIR................................................................................................................................285 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...........................................................................................287 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...........................................................................................287 TROUBLESHOOTING.............................................................................................................................289 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................................................290 SEQUENCE OF EVENTS IN TROUBLESHOOTING...................................................................................................291 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...............................................................................................292 CHECKS BEFORE TROUBLESHOOTING...........................................................................................................301 ELECTRICAL CIRCUIT DIAGRAM..............................................................................................................302 POSITION OF CONNECTORS FOR TROUBLESHOOTING..............................................................................................306 CONNECTION TABLE FOR CONNECTOR..........................................................................................................310 EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM......................................................................318 DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER........................................................321 ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE..............................................................................325 METHOD OF USING JUDGEMENT TABLE.........................................................................................................328 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................................330 TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)...........................................................................333 ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS...............................................................................334 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM...........................................335 E-1 [Abnormality in power source system or controller] is displayed (All lamps OFF).................................................336 E-2 [Short circuit in governor motor] is displayed..................................................................................340 E-3 [Abnormality in battery relay] is displayed.....................................................................................341 E-4 [Disconnection in wiring harness of governor motor] is displayed................................................................342 E-5 [Abnormality in governor potentiometer] is displayed............................................................................344 E-6 [Abnormality in fuel control dial] is displayed.................................................................................346 E-7 [Abnormality in No. 2 throttle signal] is displayed.............................................................................348 E-8 Engine does not start...........................................................................................................350 E-9 Engine rotation is irregular....................................................................................................352 a) Idling rotation is irregular.................................................................................................352 b) There is hunting.............................................................................................................354 E-10 Lack of output power (max. engine speed is too low)............................................................................356 E-11 Engine does not stop...........................................................................................................358 E-12 Automatic warming-up operation is defective....................................................................................360 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)......................................................................................361 CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS.............................................363 C-1[OFF] Self-diagnostic display of controller does not light up....................................................................364 C-2 [Short circuit in 2-stage relief solenoid valve system] is displayed............................................................365 C-3 [Short circuit in arm half flow solenoid valve system] is displayed.............................................................366 C-4 [Short circuit in swing brake solenoid valve system] is displayed...............................................................367 C-5 [Short circuit in travel speed solenoid valve system] is displayed..............................................................368 C-6 [ Short circuit in CO cancel solenoid valve system] is displayed...............................................................369 C-7 [Short circuit in TVC solenoid sysem (1)] is displayed..........................................................................370 C-8 [Short circuit in TVC solenoid valve system (2)] is displayed...................................................................371 C-9 [ Disconnection in 2-stage relief solenoid valve system] is displayed...........................................................372 C-10 [Disconnection in arm half flow solenoid valve system] is displayed............................................................373 C-11 [Disconnection in swing brake solenoid valve system]...........................................................................374 C-12 [Disconnection in travel speed solenoid valve system] is displayed.............................................................375 C-13 [Disconnection in CO cancel solenoid valve system] is displayed................................................................376 C-14 [Disconnection in TVC solenoid valve system] is displayed......................................................................377 C-15 [Abnormality in No. 2 throttle signal system] is displayed.....................................................................378 C-16 [Abnormality in throttle signal system] is displayed...........................................................................379 C-17 [ Abnormality in front pump pressure sensor signal system] is displayed........................................................380 C-18 [Abnormality in rear pump pressure sensor signal system] is displayed..........................................................382 C-19 [Abnormality in pressure sensor power source system] is displayed.............................................................384 C-20 [Abnormality in engine speed sensor system] is displayed.......................................................................386 C-21 Abnormality in auto-deceleration signal output system] is displayed............................................................387 C-22 [Abnormality in overheat signal system] is displayed...........................................................................388 C-23 [Controller abnormal system] is displayed......................................................................................389 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE).........................................................................391 F-1 Pump controller monitor does not display [Work equipment - Swing oil pressure switch]...........................................392 F-2 Pump controller monitor does not display [Travel oil pressure switch]...........................................................393 F-3 Pump Controller monitor does not display [Swing lock switch]....................................................................394 F-4 Pump controller monitor does not display [Travel speed switch]..................................................................395 F-5 Pump controller monitor does not display [Auto-deceleration switch].............................................................396 F-6 Pump controller monitor does not display [Power maximizing switch]..............................................................397 F-7 Pump controller monitor does not display [decimal point of [Engine speed sensor]...............................................398 F-8 Pump controller working mode display does not switch............................................................................399 F-9 Pump controller power set display does not switch...............................................................................400 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).............................................................................401 H-1 Speeds of work equipment, travel, swing are all slow............................................................................402 H-2 There is excessive drop in engine speed, or’ engine stalls......................................................................404 H-3 Work equipment, travel, swing do not move, or speed is extremely slow...........................................................406 H-4 Work equipment, travel, swing lack power........................................................................................408 H-5 Power set selection system does not switch......................................................................................408 H-6 Abnormal noise generated (from around pump).....................................................................................409 H-7 Auto-deceleration does not work.................................................................................................409 H-8 Boom, arm speed is extremely slow...............................................................................................410 H-9 Work equipment (boom, arm, bucket) speed is slow................................................................................412 H-10 When boom and arm are operated simultaneously, boom is slow....................................................................414 H-11 Work equipment (boom, arm, bucket) lacks power.................................................................................414 H-12 Excessive hydraulic drift......................................................................................................414 H-13 Excessive time lag.............................................................................................................416 H-14 Does not enter F.0 mode (Half flow functiuon)..................................................................................416 H-15 When arm and swing are operated simultaneously, arm is slow....................................................................416 H-16 When machine is traveling, it deviates naturally to one side...................................................................418 a) Deviates in same direction both in forward and reverse.......................................................................418 b) Deviates in different direction in forward and reverse (See Fig. I)..........................................................420 H-17 Excessive deviation during compound operations.................................................................................421 H-18 Excessive deviation when starting..............................................................................................422 H-19 Travel lacks power (or speed is slow)..........................................................................................424 H-20 Travel speed does not switch...................................................................................................424 H-21 Machine does not move (one side only)..........................................................................................425 H-22 Does not swing.................................................................................................................426 H-23 Swing speed is slow or acceleration is poor....................................................................................428 H-24 Excessive overrun when stopping swing..........................................................................................429 H-25 Excessive shock when stopping swing............................................................................................429 H-26 Excessive abnormal noise when stopping swing...................................................................................430 H-27 Excessive hydraulic drift of swing.............................................................................................430 H-28 When operated simultaneously with arm, swing speed is slow.....................................................................430 TABLE OF FAILURE MODES AND CAUSES...................................................................................................431 TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)..............................................................................................433 P-1 Monitor panel lamps do not light up for 3 seconds when starting switch is turned ON.............................................434 a) No monitor panel lamps light up..............................................................................................434 b) Some monitor panel lamps do not light up.....................................................................................434 P-2 Monitor panel lamps all light up when starting switch is turned ON, but do not go out...........................................435 P-3 When starting switch is turned ON (engine stopped), CHECK items flash (Levels for CHECK items are as specified).................436 a) (Coolant level) flashes......................................................................................................436 b) Engine oil level) flashes....................................................................................................437 c) (Hydraulic oil level) flashes................................................................................................438 P-4 Preheating is not being used, but preheating display lights up..................................................................439 P-5 When starting switch is turned ON and engine is started, CHECK items flash......................................................441 a) Alternator system............................................................................................................441 b) Engine oil pressure system...................................................................................................441 P-6 When starting switch is turned ON (engine stopped), CAUTION items flash.........................................................442 P-7 When starting switch is turned ON and engine is started, CAUTION items flash (When there is no abnormality in CHECK items)......443 a) (Engine oil pressure) flashes................................................................................................443 b) (Coolant level) flashes......................................................................................................443 c) (Coolant temperature) flashes................................................................................................444 d) (Charge) flashes.............................................................................................................444 e) (Fuel level) flashes.........................................................................................................445 P-8 (a) When starting switch is turned ON (engine buzzer does not sound for 1 second CAUTION item is flashing but no buzzer soun....446 P-8 (b) There is no abnormality display on the monitor, but the buzzer sounds.......................................................446 P-9 Panel lighting of monitor panel does not light up (liquid crystal display is normal)............................................447 P-10 Coolant temperature shows abnormally low temperature...........................................................................448 P-11 Coolant temperature gauge gives no display (during operation, no level of gauge is displayed)..................................448 P-12 Fuel gauge always displays FULL................................................................................................449 P-13 Fuel gauge gives no display....................................................................................................449 P-14 (a) Lamps do not light up......................................................................................................450 P-14 (b) Lamps light up even when lamp switch is not operated.......................................................................450 P-15 (a) Wipers do not work.........................................................................................................452 P-15 (b) Wipers work even when wiper switch is not operated.........................................................................452 P-16 (a) Fan does not work..........................................................................................................454 P-16 (b) Fan works even when fan switch is not operated.............................................................................454 P-17 Working mode does not switch...................................................................................................456 P-18 Power set does not switch......................................................................................................457 P-19 Auto-deceleration does not switch (Does not enter auto-deceleration; auto-deceleration is not canceled)........................458 P-20 Travel speed does not switch between Hi and Lo.................................................................................459 P-21 Warming-up operation is not carried out below 30°C, or warming-up operation is not canceled even when temperature goes abov....460 P-22 Even when swing lock switch is turned ON (LOCK), swing lock lamp on monitor panel does not light up............................461 30 DISASSEMBLY AND ASSEMBLY.....................................................................................................................467 METHOD OF USING MANUAL......................................................................................................................469 PRECAUTIONS WHEN CARRYING OUT OPERATION.....................................................................................................470 SPECIAL TOOL LIST...........................................................................................................................472 WEIGHT TABLE................................................................................................................................479 TIGHTENING TORQUES AND STANDARD VALUES TABLE................................................................................................484 STARTING MOTOR ASSEMBLY.....................................................................................................................490 ALTERNATOR ASSEMBLY.........................................................................................................................490 ENGINE OIL COOLER ASSEMBLY..................................................................................................................492 FUEL INJECTION PUMP ASSEMBLY................................................................................................................494 WATER PUMP ASSEMBLY.........................................................................................................................496 NOZZLE HOLDER ASSEMBLY......................................................................................................................498 TURBOCHARGER ASSEMBLY.......................................................................................................................500 THERMOSTAT ASSEMBLY.........................................................................................................................500 ENGINE FRONT OIL SEAL.......................................................................................................................502 ENGINE REAR OIL SEAL .......................................................................................................................504 GOVERNOR MOTOR ASSEMBLY ...................................................................................................................506 CYLINDER HEAD ASSEMBLY ....................................................................................................................508 AFTERCOOLER CORE ASSEMBLY .................................................................................................................512 HYDRAULIC COOLER ASSEMBLY...................................................................................................................514 RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY...................................................................................................516 ENGINE, HYDRAULIC PUMP ASSEMBLY ...........................................................................................................518 DAMPER ASSEMBLY ............................................................................................................................522 CENTER SWIVEL JOINT ASSEMBLY...............................................................................................................524 FINAL DRIVE ASSEMBLY........................................................................................................................526 INSTALLATION OF FINAL DRIVE ASSEMBLY ......................................................................................................526 ASSEMBLY OF FINAL DRIVE ASSEMBLY ..........................................................................................................530 TRAVEL MOTOR ASSEMBLY ......................................................................................................................536 SPROCKET ASSEMBLY .........................................................................................................................550 SWING MOTOR ASSEMBLY ......................................................................................................................550 SWING MACHINERY ASSEMBLY ..................................................................................................................560 REVOLVING FRAME ASSEMBLY ..................................................................................................................570 SWING CIRCLE ASSEMBLY......................................................................................................................572 IDLER, RECOIL SPRING ASSEMBLY..............................................................................................................572 CARRIER ROLLER ASSEMBLY ...................................................................................................................576 TRACK ROLLER ASSEMBLY......................................................................................................................576 CHARGING PUMP ASSEMBLY.....................................................................................................................578 TRACK SHOE ASSEMBLY .......................................................................................................................578 HYDRAULIC PUMP ASSEMBLY....................................................................................................................580 HYDRAULIC PUMP INPUT SHAFT OIL SEAL .......................................................................................................606 CONTROL VALVE ASSEMBLY ....................................................................................................................608 MAIN RELIEF VALVE ASSEMBLY ...............................................................................................................614 TVC VALVE ASSEMBLY .......................................................................................................................616 SERVO ASSEMBLY.............................................................................................................................616 CO-NC VALVE ASSEMBLY.......................................................................................................................616 WORK EQUIPMENT PPC VALVE ASSEMBLY .........................................................................................................618 TRAVEL PPC VALVE ASSEMBLY .................................................................................................................620 BOOM HOLDING VALVE ASSEMBLY.................................................................................................................622 PPC SHUTTLE VALVE ASSEMBLY..................................................................................................................624 BOOM CYLINDER ASSEMBLY .....................................................................................................................626 ARM CYLINDER ASSEMBLY .....................................................................................................................630 BUCKET CYLINDER ASSEMBLY ...................................................................................................................634 BOTTOM DUMP CYLINDER ASSEMBLY..............................................................................................................638 HYDRAULIC CYLINDER ASSEMBLY ................................................................................................................640 WORK EQUIPMENT ASSEMBLY.....................................................................................................................646 BUCKET ASSEMBLY ............................................................................................................................648 ARM ASSEMBLY................................................................................................................................652 ARM, BUCKET ASSEMBLY . ...................................................................................................................656 BOOM ASSEMBLY .............................................................................................................................658 OPERATOR’S CAB ASSEMBLY....................................................................................................................662 COUNTERWEIGHT ..............................................................................................................................662 THROTTLE CONTROLLER ........................................................................................................................664 PUMP CONTROLLER ASSEMBLY...................................................................................................................664 MONITOR PANEL ASSEMBLY ....................................................................................................................664 PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT ...................................................................................................674 40 MAINTENANCE STANDARD.........................................................................................................................683 FINAL DRIVE.................................................................................................................................684 SWING MACHINERY ............................................................................................................................688 SWING CIRCLE ...............................................................................................................................692 TRACK FRAME AND RECOIL SPRING ..............................................................................................................694 IDLER ......................................................................................................................................698 TRACK ROLLER ...............................................................................................................................702 CARRIER ROLLER .............................................................................................................................704 TRACK SHOE .................................................................................................................................706 CHARGING PUMP AND RELIEF VALVE .............................................................................................................712 CONTROL VALVE ..............................................................................................................................713 TRAVEL SHUTTLE VALVE .......................................................................................................................728 SWING MOTOR ................................................................................................................................729 TRAVEL MOTOR ...............................................................................................................................730 PPC VALVE ..................................................................................................................................732 PPC SHUTTLE VALVE ..........................................................................................................................734 BOOM HOLDING VALVE .........................................................................................................................735 HYDRAULIC CYLINDER .........................................................................................................................736 WORK EQUIPMENT..............................................................................................................................740
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