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Komatsu PC300-6 PC300LC-6 Custom Excavator Shop Manual PDF
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Komatsu PC300-6 PC300LC-6 Custom Excavator Shop Manual SEBM007201 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PC300-6 CUSTOM 30001 and up
PC300-6 CUSTOM 30001 and up
PC300LC-6 CUSTOM 30001 and up
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Description
Komatsu PC300-6 PC300LC-6 Custom Excavator Shop Manual SEBM007201 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC300-6 PC300LC-6 Custom Excavator Shop Manual SEBM007201 – PDF DOWNLOAD
Language : English
Pages : 582
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Komatsu PC300-6 PC300LC-6 Custom Excavator Shop Manual SEBM007201 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PC300-6 CUSTOM 30001 and up
PC300-6 CUSTOM 30001 and up
PC300LC-6 CUSTOM 30001 and up
COVER 1
CONTENTS 2
01 GENERAL 24
SPECIFICATION DRAWINGS 25
SPECIFICATIONS 26
WEIGHT TABLE 28
FUEL, COOLANT AND LUBRICANTS 30
10 STRUCTURE AND FUNCTION 32
PARTS RELATED TO ENGINE 33
RADIATOR, OIL COOLER 35
POWER TRAIN 36
FINAL DRIVE 37
SWING CIRCLE 38
SWING MACHINERY 39
TRACK FRAME, RECOIL SPRING 40
TRACK SHOE 41
HYDRAULIC PIPING DRAWING 42
HYDRAULIC CIRCUIT DIAGRAM 43
HYDRAULIC TANK, HYDRAULIC FILTER 44
HYDRAULIC PUMP 45
CONTROL VALVE 64
SUCTION SAFETY VALVE 73
CLSS 74
SWING MOTOR 115
CENTER SWIVEL JOINT 119
TRAVEL MOTOR 120
VALVE CONTROL 129
WORK EQUIPMENT, SWING PPC VALVE 130
TRAVEL PPC VALVE 134
SERVICE PPC VALVE 138
PPC SAFETY LOCK VALVE 141
PPC ACCUMULATOR 141
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE 142
SOLENOID VALVE 149
BOOM HOLDING VALVE 153
HYDRAULIC CYLINDER 156
WORK EQUIPMENT 157
ACTUAL ELECTRIC WIRING DIAGRAM 158
ELECTRIC CIRCUIT DIAGRAM 160
ENGINE CONTROL SYSTEM 163
ELECTRIC CONTROL SYSTEM 164
MACHINE MONITOR SYSTEM 168
SENSORS 171
20 TESTING AND ADJUSTING 173
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 174
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 175
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 183
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 185
MEASURING ENGINE SPEED 186
MEASURING EXHAUST COLOR 187
ADJUSTING VALVE CLEARANCE 188
MEASURING COMPRESSION PRESSURE 189
MEASURING BLOW-BY PRESSURE 189
TESTING AND ADJUSTING FUEL INJECTION TIMING 190
MEASURING ENGINE OIL PRESSURE 191
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 192
TESTING AND ADJUSTING WATER PUMP BELT TENSION 192
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 193
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 194
ADJUSTING FUEL CONTROL LEVER 195
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 197
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 200
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE 202
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE 205
TESTING SOLENOID VALVE OUTPUT PRESSURE 207
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE 208
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 210
TESTING TRAVEL DEVIATION 211
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 212
MEASURING OIL LEAKAGE 214
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 216
TESTING CLEARANCE OF SWING CIRCLE BEARING 217
TESTING AND ADJUSTING TRACK SHOE TENSION 218
BLEEDING AIR 219
TROUBLESHOOTING 221
POINTS TO REMEMBER WHEN TROUBLESHOOTING 222
SEQUENCE OF EVENTS IN TROUBLESHOOTING 223
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 224
CHECKS BEFORE TROUBLESHOOTING 232
CONNECTOR TYPES AND MOUNTING LOCATIONS 233
CONNECTOR ARRANGEMENT DIAGRAM 234
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 236
METHOD OF USING TROUBLESHOOTING CHARTS 246
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 248
METHOD OF USING TROUBLESHOOTING CHARTS 249
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 253
S-2 ENGINE DOES NOT START 254
(1) ENGINE DOES NOT TURN 254
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 255
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 256
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 257
S-4 ENGINE STOPS DURING OPERATIONS 258
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 259
S-6 ENGINE LACKS OUTPUT (NO POWER) 260
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 261
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 262
S-9 OIL BECOMES CONTAMINATED QUICKLY 263
S-10 FUEL CONSUMPTION IS EXCESSIVE 264
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 265
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 266
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL ) 267
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 268
S-15 ABNORMAL NOISE IS MADE 269
S-16 VIBRATION IS EXCESSIVE 270
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 271
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM 272
E MODE ELECTRICAL SYSTEM DIAGRAM 274
E-1 ABNORMALITY IN PUMP TVC CONTROL SYSTEM 275
a) ENGINE STALLS WHEN FUEL CONTROL LEVER IS AT FULL (FUEL CONTROL LEVER SWITCH OFF) 275
b) ENGINE STALLS BELOW MIDRANGE SPEED {ENGINE SPEED: BELOW 1600 rpm (FUEL CONTROL LEVER LIMIT SWITCH ON)} 276
c) FUEL CONTROL LEVER IS AT FULL, WORK EQUIPMENT SPEED IS SLOW OR LACKS POWER 277
E-2 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEM 278
a) IS NOT ACTUATED (SAFETY LOCK IS NOT RELEASED) 278
b) REMAINS ACTUATED (SAFETY LOCK IS NOT APPLIED) 279
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM 280
a) IS NOT ACTUATED (CANNOT SWING) 280
b) REMAINS ACTUATED (SWING CANNOT BE LOCKED) 281
E-4 STEERING DOES NOT TURN EASILY (ABNORMALITY IN PUMP MERGE/DIVIDER SOLENOID SYSTEM) 282
E-5 ABNORMALITY IN TRAVEL SPEED SOLENOID SYSTEM 284
a) TRAVEL SPEED DOES NOT CHANGE TO HI (TRAVEL SPEED STAYS IN LO) 284
b) TRAVEL SPEED DOES NOT CHANGE TO LO (TRAVEL SPEED STAYS IN HI) 285
E-6 ABNORAMLITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START) 286
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 288
TABLE OF FAILURE MODES AND CAUSES 289
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER 293
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 295
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE 296
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP) 296
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 297
H-6 BOOM IS SLOW OR LACKS POWER 298
H-7 ARM IS SLOW OR LACKS POWER 300
H-8 BUCKET IS SLOW OR LACKS POWER 302
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL) 302
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET) 303
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) 304
H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED 304
H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 304
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW 305
H-15 IN SWING + ARM OUT, ARM OUT IS SLOW 305
H-16 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY 305
H-17 TRAVEL DEVIATION 306
H-18 TRAVEL SPEED IS SLOW 307
H-19 STEERING DOES NOT TURN EASILY OR LACKS POWER 309
H-20 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED 311
H-21 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) 311
H-22 DOES NOT SWING 312
H-23 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW 313
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING 315
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 316
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 316
H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING 317
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 318
MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM 319
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS) 320
M-2 WHEN STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT 320
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS 321
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP) 321
b) SWING LOCK PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP) 321
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP 321
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 321
M-4 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP 322
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 322
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP 323
M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UP 323
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL) 324
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING 324
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE 325
a) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND GOES NOT MOVE 325
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE 325
c) COOLANT TEMPERATURE GAUGE GOES OUT 325
M-11 ABNORMALITY IN FUEL GAUGE 326
a) ALL FUEL GAUGE SEGMENTS GO OUT 326
b) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL 326
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL 326
M-12 DEFECTIVE OPERATION OF ALARM BUZZER 328
a) BUZZER DOES NOT SOUND 328
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP 328
M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE 329
a) CHARGE CAUTION LAMP LIGHTS UP 329
b) CHARGE CAUTION LAMP DOES NOT LIGHT UP 329
M-14 NIGHT LIGHTING DOES NOT LIGHT UP 330
a) GAUGE LIGHTING DOES NOT LIGHT UP 330
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY) 330
M-15 WIPER DOES NOT MOVE, OR DOES NOT STOP MOVING 331
a) WIPER DOES NOT MOVE WHEN WIPER SWITCH IS TURNED TO ON 331
b) WIPER MOVES EVEN WHEN WIPER SWITCH IS NOT TURNED TO ON 331
M-16 HEATER DOES NOT WORK 332
a) DOES NOT WORK AT EITHER HI OR LO 332
b) DOES NOT WORK AT LO ONLY 332
c) DOES NOT WORK AT HI ONLY 332
30 DISASSEMBLY AND ASSEMBLY 333
METHOD OF USING MANUAL 335
PRECAUTIONS WHEN CARRYING OUT OPERATION 337
SPECIAL TOOL LIST 339
SKETCHES OF SPECIAL TOOLS 344
STARTING MOTOR ASSEMBLY 349
REMOVAL AND INSTALLATION 349
ALTERNATOR ASSEMBLY 350
REMOVAL AND INSTALLATION 350
ENGINE OIL COOLER ASSEMBLY 351
REMOVAL AND INSTALLATION 351
FUEL INJECTION PUMP ASSEMBLY 352
REMOVAL 352
INSTALLATION 353
WATER PUMP ASSEMBLY 354
REMOVAL AND INSTALLATION 354
NOZZLE HOLDER ASSEMBLY 355
REMOVAL AND INSTALLATION 355
TURBOCHARGER ASSEMBLY 356
REMOVAL AND INSTALLATION 356
THERMOSTAT ASSEMBLY 357
REMOVAL AND INSTALLATION 357
ENGINE FRONT SEAL 358
REMOVAL 358
INSTALLATION 359
CYLINDER HEAD ASSEMBLY 360
REMOVAL 360
INSTALLATION 362
AFTERCOOLER ASSEMBLY 365
REMOVAL AND INSTALLATION 365
HYDRAULIC COOLER ASSEMBLY 366
REMOVAL AND INSTALLATION 366
RADIATOR, HYDRAULIC COOLER ASSEMBLY 367
REMOVAL 367
INSTALLATION 368
ENGINE, MAIN PUMP ASSEMBLY 369
REMOVAL 369
INSTALLATION 371
DAMPER ASSEMBLY 372
REMOVAL AND INSTALLATION 372
FUEL TANK ASSEMBLY 373
REMOVAL AND INSTALLATION 373
CENTER SWIVEL JOINT ASSEMBLY 374
REMOVAL AND INSTALLATION 374
DISASSEMBLY AND ASSEMBLY 375
FINAL DRIVE ASSEMBLY 376
REMOVAL AND INSTALLATION 376
DISASSEMBLY 377
ASSEMBLY 381
TRAVEL MOTOR ASSEMBLY 387
DISASSEMBLY 387
ASSEMBLY 392
SPROCKET 401
REMOVAL AND INSTALLATION 401
SWING MOTOR ASSEMBLY 402
REMOVAL AND INSTALLATION 402
DISASSEMBLY 403
ASSEMBLY 406
SWING MACHINERY ASSEMBLY 413
REMOVAL AND INSTALLATION 413
DISASSEMBLY 414
ASSEMBLY 418
REVOLVING FRAME ASSEMBLY 423
REMOVAL 423
INSTALLATION 424
SWING CIRCLE ASSEMBLY 425
REMOVAL AND INSTALLATION 425
IDLER, RECOIL SPRING ASSEMBLY 426
REMOVAL AND INSTALLATION 426
IDLER ASSEMBLY 427
DISASSEMBLY 427
ASSEMBLY 428
RECOIL SPRING ASSEMBLY 430
DISASSEMBLY 430
ASSEMBLY 431
TRACK ROLLER ASSEMBLY 432
REMOVAL AND INSTALLATION 432
DISASSEMBLY 433
ASSEMBLY 434
CARRIER ROLLER ASSEMBLY 436
REMOVAL AND INSTALLATION 436
DISASSEMBLY 437
ASSEMBLY 439
TRACK SHOE ASSEMBLY 441
REMOVAL AND INSTALLATION 441
HYDRAULIC TANK ASSEMBLY 442
REMOVAL 442
INSTALLATION 443
CONTROL PUMP ASSEMBLY 444
REMOVAL AND INSTALLATION 444
MAIN PUMP ASSEMBLY 445
REMOVAL 445
INSTALLATION 446
DISASSEMBLY 447
ASSEMBLY 453
MAIN PUMP INPUT SHAFT OIL SEAL 467
REMOVAL AND INSTALLATION 467
CONTROL VALVE ASSEMBLY 468
REMOVAL 468
INSTALLATION 470
DISASSEMBLY 471
ASSEMBLY 475
PUMP MERGE/DIVIDER VALVE ASSEMBLY 480
DISASSEMBLY AND ASSEMBLY 480
PRESSURE COMPENSATION VALVE ASSEMBLY 481
DISASSEMBLY AND ASSEMBLY 481
SERVO VALVE ASSEMBLY FOR FRONT PUMP 482
REMOVAL AND INSTALLATION 482
SERVO VALVE ASSEMBLY FOR REAR PUMP 483
REMOVAL AND INSTALLATION 483
PPC LOCK AND SWING BRAKE SOLENOID VALVE ASSEMBLY 484
REMOVAL AND INSTALLATION 484
MERGE/FLOW DIVIDER AND TRAVEL HI/LO SOLENOID VALVE ASSEMBLY 485
REMOVAL AND INSTALLATION 485
WORK EQUIPMENT PPC VALVE ASSEMBLY 486
REMOVAL AND INSTALLATION 486
DISASSEMBLY 487
ASSEMBLY 488
TRAVEL PPC VALVE ASSEMBLY 489
REMOVAL AND INSTALLATION 489
DISASSEMBLY 490
ASSEMBLY 491
PPC SHUTTLE VALVE ASSEMBLY 492
REMOVAL 492
INSTALLATION 493
DISASSEMBLY 494
ASSEMBLY 495
BOOM LOCK VALVE ASSEMBLY 496
REMOVAL AND INSTALLATION 496
DISASSEMBLY AND ASSEMBLY 497
BOOM CYLINDER ASSEMBLY 498
REMOVAL 498
INSTALLATION 499
ARM CYLINDER ASSEMBLY 500
REMOVAL 500
INSTALLATION 501
BUCKET CYLINDER ASSEMBLY 502
REMOVAL 502
INSTALLATION 503
HYDRAULIC CYLINDER ASSEMBLY 504
DISASSEMBLY 504
ASSEMBLY 506
WORK EQUIPMENT ASSEMBLY 508
REMOVAL 508
INSTALLATION 509
BUCKET ASSEMBLY 510
REMOVAL 510
INSTALLATION 511
ARM ASSEMBLY 512
REMOVAL 512
INSTALLATION 513
BUCKET, ARM ASSEMBLY 514
REMOVAL 514
INSTALLATION 515
BOOM ASSEMBLY 516
REMOVAL 516
INSTALLATION 517
OPERATOR’S CAB ASSEMBLY 518
REMOVAL AND INSTALLATION 518
MONITOR ASSEMBLY 519
REMOVAL AND INSTALLATION 519
COUNTERWEIGHT ASSEMBLY 520
REMOVAL AND INSTALLATION 520
CONTROL STAND CASE 521
REMOVAL 521
INSTALLATION 522
AIR CONDITIONER COMPRESSOR ASSEMBLY 523
REMOVAL AND INSTALLATION 523
CONDENSER ASSEMBLY 524
REMOVAL AND INSTALLATION 524
AIR CONDITIONER UNIT ASSEMBLY 525
REMOVAL 525
INSTALLATION 526
40 MAINTENANCE STANDARD 527
ENGINE MOUNT 528
SWING MACHINERY 529
SWING CIRCLE 531
FINAL DRIVE 532
TRACK FRAME AND RECOIL SPRING 534
IDLER 535
CARRIER ROLLER 537
TRACK ROLLER 538
TRACK 539
HYDRAULIC PUMP 541
CONTROL PUMP AND RELIEF VALVE 542
CONTROL VALVE 543
SUCTION-SAFETY VALVE 549
SWING MOTOR 550
TRAVEL MOTOR 551
WORK EQUIPMENT, SWING PPC VALVE 552
TRAVEL PPC VALVE 553
SERVICE PPC VALVE 554
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE 555
CENTER SWIVEL JOINT 556
BOOM HOLDING VALVE 557
HYDRAULIC CYLINDER 558
WORK EQUIPMENT 559
90 OTHERS 564
HYDRAULIC PIPING DIAGRAM (10-12) 565
HYDRAULIC CIRCUIT DIAGRAM (10-13) 566
OPERATION FOR EACH FUNCTION OF CLSS (10-50) 567
OPERATION OF WHOLE CLSS SYSTEM 568
1 WHEN ALL WORK EQUIPMENT IS AT NEUTRAL (10-68) 568
2 PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY (10-70) 569
3 PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY (10-72) 570
4 PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY (10-74) 571
5 PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY (10-76) 572
6 PUMP FLOW DIVIDED, TRAVEL OPERATED INDEPENDENTLY (10-78) 573
7 PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY (10-80) 574
8 PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY (10-82) 575
9 PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY (10-84) 576
10 PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY (10-86) 577
ACTUAL ELECTRIC WIRING DIAGRAM (10-134) 578
ACTUAL ELECTRIC WIRING DIAGRAM (10-135) 579
ELECTRIC CIRCUIT DIAGRAM (10-136) 580
ELECTRIC CIRCUIT DIAGRAM (10-137) 581
CONNECTOR ARRANGEMENT DIAGRAM (20-114) 582
CONTENTS 2
01 GENERAL 24
SPECIFICATION DRAWINGS 25
SPECIFICATIONS 26
WEIGHT TABLE 28
FUEL, COOLANT AND LUBRICANTS 30
10 STRUCTURE AND FUNCTION 32
PARTS RELATED TO ENGINE 33
RADIATOR, OIL COOLER 35
POWER TRAIN 36
FINAL DRIVE 37
SWING CIRCLE 38
SWING MACHINERY 39
TRACK FRAME, RECOIL SPRING 40
TRACK SHOE 41
HYDRAULIC PIPING DRAWING 42
HYDRAULIC CIRCUIT DIAGRAM 43
HYDRAULIC TANK, HYDRAULIC FILTER 44
HYDRAULIC PUMP 45
CONTROL VALVE 64
SUCTION SAFETY VALVE 73
CLSS 74
SWING MOTOR 115
CENTER SWIVEL JOINT 119
TRAVEL MOTOR 120
VALVE CONTROL 129
WORK EQUIPMENT, SWING PPC VALVE 130
TRAVEL PPC VALVE 134
SERVICE PPC VALVE 138
PPC SAFETY LOCK VALVE 141
PPC ACCUMULATOR 141
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE 142
SOLENOID VALVE 149
BOOM HOLDING VALVE 153
HYDRAULIC CYLINDER 156
WORK EQUIPMENT 157
ACTUAL ELECTRIC WIRING DIAGRAM 158
ELECTRIC CIRCUIT DIAGRAM 160
ENGINE CONTROL SYSTEM 163
ELECTRIC CONTROL SYSTEM 164
MACHINE MONITOR SYSTEM 168
SENSORS 171
20 TESTING AND ADJUSTING 173
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 174
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 175
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 183
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 185
MEASURING ENGINE SPEED 186
MEASURING EXHAUST COLOR 187
ADJUSTING VALVE CLEARANCE 188
MEASURING COMPRESSION PRESSURE 189
MEASURING BLOW-BY PRESSURE 189
TESTING AND ADJUSTING FUEL INJECTION TIMING 190
MEASURING ENGINE OIL PRESSURE 191
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 192
TESTING AND ADJUSTING WATER PUMP BELT TENSION 192
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 193
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 194
ADJUSTING FUEL CONTROL LEVER 195
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 197
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 200
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE 202
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE 205
TESTING SOLENOID VALVE OUTPUT PRESSURE 207
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE 208
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 210
TESTING TRAVEL DEVIATION 211
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 212
MEASURING OIL LEAKAGE 214
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 216
TESTING CLEARANCE OF SWING CIRCLE BEARING 217
TESTING AND ADJUSTING TRACK SHOE TENSION 218
BLEEDING AIR 219
TROUBLESHOOTING 221
POINTS TO REMEMBER WHEN TROUBLESHOOTING 222
SEQUENCE OF EVENTS IN TROUBLESHOOTING 223
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 224
CHECKS BEFORE TROUBLESHOOTING 232
CONNECTOR TYPES AND MOUNTING LOCATIONS 233
CONNECTOR ARRANGEMENT DIAGRAM 234
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 236
METHOD OF USING TROUBLESHOOTING CHARTS 246
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 248
METHOD OF USING TROUBLESHOOTING CHARTS 249
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 253
S-2 ENGINE DOES NOT START 254
(1) ENGINE DOES NOT TURN 254
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 255
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 256
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 257
S-4 ENGINE STOPS DURING OPERATIONS 258
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 259
S-6 ENGINE LACKS OUTPUT (NO POWER) 260
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 261
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 262
S-9 OIL BECOMES CONTAMINATED QUICKLY 263
S-10 FUEL CONSUMPTION IS EXCESSIVE 264
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 265
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 266
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL ) 267
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 268
S-15 ABNORMAL NOISE IS MADE 269
S-16 VIBRATION IS EXCESSIVE 270
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 271
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM 272
E MODE ELECTRICAL SYSTEM DIAGRAM 274
E-1 ABNORMALITY IN PUMP TVC CONTROL SYSTEM 275
a) ENGINE STALLS WHEN FUEL CONTROL LEVER IS AT FULL (FUEL CONTROL LEVER SWITCH OFF) 275
b) ENGINE STALLS BELOW MIDRANGE SPEED {ENGINE SPEED: BELOW 1600 rpm (FUEL CONTROL LEVER LIMIT SWITCH ON)} 276
c) FUEL CONTROL LEVER IS AT FULL, WORK EQUIPMENT SPEED IS SLOW OR LACKS POWER 277
E-2 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEM 278
a) IS NOT ACTUATED (SAFETY LOCK IS NOT RELEASED) 278
b) REMAINS ACTUATED (SAFETY LOCK IS NOT APPLIED) 279
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM 280
a) IS NOT ACTUATED (CANNOT SWING) 280
b) REMAINS ACTUATED (SWING CANNOT BE LOCKED) 281
E-4 STEERING DOES NOT TURN EASILY (ABNORMALITY IN PUMP MERGE/DIVIDER SOLENOID SYSTEM) 282
E-5 ABNORMALITY IN TRAVEL SPEED SOLENOID SYSTEM 284
a) TRAVEL SPEED DOES NOT CHANGE TO HI (TRAVEL SPEED STAYS IN LO) 284
b) TRAVEL SPEED DOES NOT CHANGE TO LO (TRAVEL SPEED STAYS IN HI) 285
E-6 ABNORAMLITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START) 286
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 288
TABLE OF FAILURE MODES AND CAUSES 289
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER 293
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 295
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE 296
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP) 296
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 297
H-6 BOOM IS SLOW OR LACKS POWER 298
H-7 ARM IS SLOW OR LACKS POWER 300
H-8 BUCKET IS SLOW OR LACKS POWER 302
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL) 302
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET) 303
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) 304
H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED 304
H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 304
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW 305
H-15 IN SWING + ARM OUT, ARM OUT IS SLOW 305
H-16 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY 305
H-17 TRAVEL DEVIATION 306
H-18 TRAVEL SPEED IS SLOW 307
H-19 STEERING DOES NOT TURN EASILY OR LACKS POWER 309
H-20 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED 311
H-21 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) 311
H-22 DOES NOT SWING 312
H-23 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW 313
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING 315
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 316
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 316
H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING 317
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 318
MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM 319
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS) 320
M-2 WHEN STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT 320
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS 321
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP) 321
b) SWING LOCK PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP) 321
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP 321
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 321
M-4 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP 322
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 322
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP 323
M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UP 323
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL) 324
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING 324
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE 325
a) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND GOES NOT MOVE 325
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE 325
c) COOLANT TEMPERATURE GAUGE GOES OUT 325
M-11 ABNORMALITY IN FUEL GAUGE 326
a) ALL FUEL GAUGE SEGMENTS GO OUT 326
b) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL 326
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL 326
M-12 DEFECTIVE OPERATION OF ALARM BUZZER 328
a) BUZZER DOES NOT SOUND 328
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP 328
M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE 329
a) CHARGE CAUTION LAMP LIGHTS UP 329
b) CHARGE CAUTION LAMP DOES NOT LIGHT UP 329
M-14 NIGHT LIGHTING DOES NOT LIGHT UP 330
a) GAUGE LIGHTING DOES NOT LIGHT UP 330
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY) 330
M-15 WIPER DOES NOT MOVE, OR DOES NOT STOP MOVING 331
a) WIPER DOES NOT MOVE WHEN WIPER SWITCH IS TURNED TO ON 331
b) WIPER MOVES EVEN WHEN WIPER SWITCH IS NOT TURNED TO ON 331
M-16 HEATER DOES NOT WORK 332
a) DOES NOT WORK AT EITHER HI OR LO 332
b) DOES NOT WORK AT LO ONLY 332
c) DOES NOT WORK AT HI ONLY 332
30 DISASSEMBLY AND ASSEMBLY 333
METHOD OF USING MANUAL 335
PRECAUTIONS WHEN CARRYING OUT OPERATION 337
SPECIAL TOOL LIST 339
SKETCHES OF SPECIAL TOOLS 344
STARTING MOTOR ASSEMBLY 349
REMOVAL AND INSTALLATION 349
ALTERNATOR ASSEMBLY 350
REMOVAL AND INSTALLATION 350
ENGINE OIL COOLER ASSEMBLY 351
REMOVAL AND INSTALLATION 351
FUEL INJECTION PUMP ASSEMBLY 352
REMOVAL 352
INSTALLATION 353
WATER PUMP ASSEMBLY 354
REMOVAL AND INSTALLATION 354
NOZZLE HOLDER ASSEMBLY 355
REMOVAL AND INSTALLATION 355
TURBOCHARGER ASSEMBLY 356
REMOVAL AND INSTALLATION 356
THERMOSTAT ASSEMBLY 357
REMOVAL AND INSTALLATION 357
ENGINE FRONT SEAL 358
REMOVAL 358
INSTALLATION 359
CYLINDER HEAD ASSEMBLY 360
REMOVAL 360
INSTALLATION 362
AFTERCOOLER ASSEMBLY 365
REMOVAL AND INSTALLATION 365
HYDRAULIC COOLER ASSEMBLY 366
REMOVAL AND INSTALLATION 366
RADIATOR, HYDRAULIC COOLER ASSEMBLY 367
REMOVAL 367
INSTALLATION 368
ENGINE, MAIN PUMP ASSEMBLY 369
REMOVAL 369
INSTALLATION 371
DAMPER ASSEMBLY 372
REMOVAL AND INSTALLATION 372
FUEL TANK ASSEMBLY 373
REMOVAL AND INSTALLATION 373
CENTER SWIVEL JOINT ASSEMBLY 374
REMOVAL AND INSTALLATION 374
DISASSEMBLY AND ASSEMBLY 375
FINAL DRIVE ASSEMBLY 376
REMOVAL AND INSTALLATION 376
DISASSEMBLY 377
ASSEMBLY 381
TRAVEL MOTOR ASSEMBLY 387
DISASSEMBLY 387
ASSEMBLY 392
SPROCKET 401
REMOVAL AND INSTALLATION 401
SWING MOTOR ASSEMBLY 402
REMOVAL AND INSTALLATION 402
DISASSEMBLY 403
ASSEMBLY 406
SWING MACHINERY ASSEMBLY 413
REMOVAL AND INSTALLATION 413
DISASSEMBLY 414
ASSEMBLY 418
REVOLVING FRAME ASSEMBLY 423
REMOVAL 423
INSTALLATION 424
SWING CIRCLE ASSEMBLY 425
REMOVAL AND INSTALLATION 425
IDLER, RECOIL SPRING ASSEMBLY 426
REMOVAL AND INSTALLATION 426
IDLER ASSEMBLY 427
DISASSEMBLY 427
ASSEMBLY 428
RECOIL SPRING ASSEMBLY 430
DISASSEMBLY 430
ASSEMBLY 431
TRACK ROLLER ASSEMBLY 432
REMOVAL AND INSTALLATION 432
DISASSEMBLY 433
ASSEMBLY 434
CARRIER ROLLER ASSEMBLY 436
REMOVAL AND INSTALLATION 436
DISASSEMBLY 437
ASSEMBLY 439
TRACK SHOE ASSEMBLY 441
REMOVAL AND INSTALLATION 441
HYDRAULIC TANK ASSEMBLY 442
REMOVAL 442
INSTALLATION 443
CONTROL PUMP ASSEMBLY 444
REMOVAL AND INSTALLATION 444
MAIN PUMP ASSEMBLY 445
REMOVAL 445
INSTALLATION 446
DISASSEMBLY 447
ASSEMBLY 453
MAIN PUMP INPUT SHAFT OIL SEAL 467
REMOVAL AND INSTALLATION 467
CONTROL VALVE ASSEMBLY 468
REMOVAL 468
INSTALLATION 470
DISASSEMBLY 471
ASSEMBLY 475
PUMP MERGE/DIVIDER VALVE ASSEMBLY 480
DISASSEMBLY AND ASSEMBLY 480
PRESSURE COMPENSATION VALVE ASSEMBLY 481
DISASSEMBLY AND ASSEMBLY 481
SERVO VALVE ASSEMBLY FOR FRONT PUMP 482
REMOVAL AND INSTALLATION 482
SERVO VALVE ASSEMBLY FOR REAR PUMP 483
REMOVAL AND INSTALLATION 483
PPC LOCK AND SWING BRAKE SOLENOID VALVE ASSEMBLY 484
REMOVAL AND INSTALLATION 484
MERGE/FLOW DIVIDER AND TRAVEL HI/LO SOLENOID VALVE ASSEMBLY 485
REMOVAL AND INSTALLATION 485
WORK EQUIPMENT PPC VALVE ASSEMBLY 486
REMOVAL AND INSTALLATION 486
DISASSEMBLY 487
ASSEMBLY 488
TRAVEL PPC VALVE ASSEMBLY 489
REMOVAL AND INSTALLATION 489
DISASSEMBLY 490
ASSEMBLY 491
PPC SHUTTLE VALVE ASSEMBLY 492
REMOVAL 492
INSTALLATION 493
DISASSEMBLY 494
ASSEMBLY 495
BOOM LOCK VALVE ASSEMBLY 496
REMOVAL AND INSTALLATION 496
DISASSEMBLY AND ASSEMBLY 497
BOOM CYLINDER ASSEMBLY 498
REMOVAL 498
INSTALLATION 499
ARM CYLINDER ASSEMBLY 500
REMOVAL 500
INSTALLATION 501
BUCKET CYLINDER ASSEMBLY 502
REMOVAL 502
INSTALLATION 503
HYDRAULIC CYLINDER ASSEMBLY 504
DISASSEMBLY 504
ASSEMBLY 506
WORK EQUIPMENT ASSEMBLY 508
REMOVAL 508
INSTALLATION 509
BUCKET ASSEMBLY 510
REMOVAL 510
INSTALLATION 511
ARM ASSEMBLY 512
REMOVAL 512
INSTALLATION 513
BUCKET, ARM ASSEMBLY 514
REMOVAL 514
INSTALLATION 515
BOOM ASSEMBLY 516
REMOVAL 516
INSTALLATION 517
OPERATOR’S CAB ASSEMBLY 518
REMOVAL AND INSTALLATION 518
MONITOR ASSEMBLY 519
REMOVAL AND INSTALLATION 519
COUNTERWEIGHT ASSEMBLY 520
REMOVAL AND INSTALLATION 520
CONTROL STAND CASE 521
REMOVAL 521
INSTALLATION 522
AIR CONDITIONER COMPRESSOR ASSEMBLY 523
REMOVAL AND INSTALLATION 523
CONDENSER ASSEMBLY 524
REMOVAL AND INSTALLATION 524
AIR CONDITIONER UNIT ASSEMBLY 525
REMOVAL 525
INSTALLATION 526
40 MAINTENANCE STANDARD 527
ENGINE MOUNT 528
SWING MACHINERY 529
SWING CIRCLE 531
FINAL DRIVE 532
TRACK FRAME AND RECOIL SPRING 534
IDLER 535
CARRIER ROLLER 537
TRACK ROLLER 538
TRACK 539
HYDRAULIC PUMP 541
CONTROL PUMP AND RELIEF VALVE 542
CONTROL VALVE 543
SUCTION-SAFETY VALVE 549
SWING MOTOR 550
TRAVEL MOTOR 551
WORK EQUIPMENT, SWING PPC VALVE 552
TRAVEL PPC VALVE 553
SERVICE PPC VALVE 554
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE 555
CENTER SWIVEL JOINT 556
BOOM HOLDING VALVE 557
HYDRAULIC CYLINDER 558
WORK EQUIPMENT 559
90 OTHERS 564
HYDRAULIC PIPING DIAGRAM (10-12) 565
HYDRAULIC CIRCUIT DIAGRAM (10-13) 566
OPERATION FOR EACH FUNCTION OF CLSS (10-50) 567
OPERATION OF WHOLE CLSS SYSTEM 568
1 WHEN ALL WORK EQUIPMENT IS AT NEUTRAL (10-68) 568
2 PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY (10-70) 569
3 PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY (10-72) 570
4 PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY (10-74) 571
5 PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY (10-76) 572
6 PUMP FLOW DIVIDED, TRAVEL OPERATED INDEPENDENTLY (10-78) 573
7 PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY (10-80) 574
8 PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY (10-82) 575
9 PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY (10-84) 576
10 PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY (10-86) 577
ACTUAL ELECTRIC WIRING DIAGRAM (10-134) 578
ACTUAL ELECTRIC WIRING DIAGRAM (10-135) 579
ELECTRIC CIRCUIT DIAGRAM (10-136) 580
ELECTRIC CIRCUIT DIAGRAM (10-137) 581
CONNECTOR ARRANGEMENT DIAGRAM (20-114) 582
DESCRIPTION:
Komatsu PC300-6 PC300LC-6 Custom Excavator Shop Manual SEBM007201 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PC300-6 CUSTOM 30001 and up
PC300-6 CUSTOM 30001 and up
PC300LC-6 CUSTOM 30001 and up
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
● Always wear safety glasses when hitting parts with a hammer.
● Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two 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 signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. 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 or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK:
7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK :
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
IMAGES PREVIEW OF THE MANUAL:
S.V 25/12/24
