Komatsu PC300-7, PC300LC-7, PC350-7, PC350LC-7 Shop Manual SEBM025814 PDF

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Komatsu PC300-7, PC300LC-7, PC350-7, PC350LC-7 Shop Manual SEBM025814 – PDF DOWNLOAD

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Komatsu PC300-7, PC300LC-7, PC350-7, PC350LC-7 Shop Manual SEBM025814 – PDF DOWNLOAD

Language : English
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Komatsu PC300-7, PC300LC-7, PC350-7, PC350LC-7 Shop Manual SEBM025814 – PDF DOWNLOAD

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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
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” with “Causes” are also included in this section.
Disassembly and assembly
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu PC300-7, PC300LC-7, PC350-7, PC350LC-7 Shop Manual SEBM025814 – PDF DOWNLOAD

COVER 1
CONTENTS 2
LIST OF REVISED PAGES 3
Safety 9
Safety notice 9
Foreword 11
General 11
Hoisting instructions 13
Method of disassembling, connecting push-pull type coupler 14
Coating materials 16
Standard tightening torque 18
Electric wire code 21
Conversion table 22
Units 28
01 GENERAL 29
SPECIFICATION DIMENSION DRAWINGS 30
SPECIFICATIONS 32
WEIGHT TABLE 36
1F2UEL, COOLANT, AND LUBRICANTS 40
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 41
ENGINE RELATED PARTS 42
RADIATOR • OIL COOLER • AFTERCOOLER 43
POWER TRAIN 44
FINAL DRIVE 46
SPROCKET 48
SWING MACHINERY 50
SWING CIRCLE 52
TRACK FRAME • RECOIL SPRING 54
IDLER 56
CARRIER ROLLER 58
TRACK ROLLER 59
TRACK SHOE 60
HYDRAULIC EQUIPMENT LAYOUT DRAWING 64
HYDRAULIC TANK 66
HYDRAULIC PUMP 68
VARIABLE VOLUME VALVE 89
CONTROL VALVE 92
CLSS108
SELF PRESSURE REDUCING VALVE111
SWING MOTOR114
REVERSE PREVENTION VALVE120
CENTER SWIVEL JOINT122
TRAVEL MOTOR123
TRAVEL JUNCTION VALVE133
TRAVEL PPC SHUTTLE VALVE136
VALVE CONTROL140
WORK EQUIPMENT • SWING PPC VALVE141
TRAVEL PPC VALVE145
SERVICE PPC VALVE154
SOLENOID VALVE157
PPC ACCUMULATOR159
RETURN OIL FILTER160
BOOM HYDRAULIC DRIFT PREVENTION VALVE162
QUICK RETURN VALVE168
LIFT CHECK VALVE170
ATTACHMENT CIRCUIT SELECTOR VALVE171
HYDRAULIC CYLINDER174
WORK EQUIPMENT176
AIR CONDITIONER182
ENGINE CONTROL183
ELECTRONIC CONTROL SYSTEM191
MULTI MONITOR SYSTEM215
7-SEGMENT MONITOR SYSTEM235
SENSOR242
20 TESTING AND ADJUSTING245
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS246
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS247
TESTING AND ADJUSTING255
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING256
INSPECTION AND ADJUSTMENT OF ENGINE SPEED258
MEASUREMENT OF AIR BOOST PRESSURE260
MEASUREMENT OF EXHAUST GAS COLOR261
ADJUSTMENT OF VALVE CLEARANCE262
MEASUREMENT OF COMPRESSION PRESSURE264
MEASUREMENT OF BLOW-BY PRESSURE265
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING266
MEASUREMENT OF ENGINE OIL PRESSURE268
ADJUSTMENT OF ENGINE SPEED SENSOR269
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION269
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM270
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS271
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION272
INSPECTION OF WEAR ON SPROCKET272
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL273
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE277
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE278
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE281
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE285
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE288
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE289
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT290
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT291
MEASUREMENT OF OIL LEAKAGE AMOUNT292
AIR BLEEDING OF VARIOUS PARTS294
INSPECTION PROCEDURES FOR DIODE296
SPECIAL FUNCTION OF MULTI-MONITOR PANEL297
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL323
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM340
TROUBLESHOOTING347
POINTS TO REMEMBER WHEN TROUBLESHOOTING348
SEQUENCE OF EVENTS IN TROUBLESHOOTING349
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE350
CHECKS BEFORE TROUBLESHOOTING358
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING359
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM364
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS398
T-BRANCH BOX AND T-BRANCH TABLE422
TROUBLESHOOTING WHEN SERVICE CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE INDICATED425
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE428
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE434
Service Code in Electrical System E101 (Abnormal data in Error History)436
Service Code in Electrical System E112 (Short-circuiting in normal rotation system of windshield wiper motor drive)440
Service Code in Electrical System E113 (Short-circuiting in reverse rotation system of windshield wiper motor drive)442
Service Code in Electrical System E114 (Short-circuiting in window washer drive system)444
Service Code in Electrical System E115 (Abnormal Windshield Wiper Motion)446
Service Code in Electrical System E116 (Abnormality in retracting windshield wiper)448
Service Code in Electrical System E201 (Short-circuiting in travel interlocking solenoid)450
Service Code in Electrical System E203 (Short-circuiting in swing and parking brake solenoid – in governor • pump controllersystem)454
Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)458
Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)462
Service Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid)466
Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)470
Service Code in Electrical System E213 (Disconnection in Swing Parking Brake Solenoid)474
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid)478
Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid)482
Service Code in Electrical System E216 (Disconnection in travel speed shifting solenoid)486
Service Code in Electrical System E217 (Abnormality in inputting model code)490
Service Code in Electrical System E218 Disconnection of S-NET signal)492
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid)494
Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system)495
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor)496
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor)498
Service Code in Electrical System E226 (Abnormality in Pressure sensor power source)500
Service Code in Electrical System E227 (Abnormality in engine rotation sensor in governor • pump controller system)502
Service Code in Electrical System E228 (Short-circuiting in attachment return switching relay)503
Service Code in Electrical System E232 (Short-circuiting in PC-EPC Solenoid504
Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)506
Service Code in Electrical System E238 (Disconnection in attachment return switching relay)508
Service Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate adjusting EPC) (Multi-monitor only)510
Service Code in Electrical System E246 (Disconnection in attachment oil flow rate adjusting EPC) (Multi-monitor only)511
Service Code in Electrical System E256 (Incorrect nonvolatile memory data)512
Service Code in Electrical System E304 (Short circuit of engine stop solenoid relay)514
Service Code in Electrical System E306 (Abnormality in governor potentiometer)518
Service Code in Electrical System E308 (Abnormality in fuel dial)520
Service Code in Electrical System E314 (Disconnection of engine stop solenoid relay)522
Service Code in Electrical System E315 (Short-circuiting in battery relay)526
Service Code in Electrical System E316 (Step-out in governor motor)528
Service Code in Electrical System (Disconnection E317 in governor motor Phase A and B)530
Service Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B)532
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling)534
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)534
Failure Code in Mechanical System AA10NX (Air cleaner clogging)535
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage)536
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure)540
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)541
Failure Code in Mechanical System B@BCNS (Engine cooling water overheating)542
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level)543
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)544
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)545
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE546
E-1 Engine does not start547
E-2 Engine stops while in operation556
E-3 Engine speed is irregular, or there is hunting558
E-4 Engine does not stop562
E-5 Auto-decelerator does not work566
E-6 Auto engine warm-up device does not work567
E-7 Preheater does not work568
E-8 All work equipment, swing and travel do not move570
E-9 One-touch Power Max Switch does not work572
E-10 No display in monitor panel at all574
E-11 Part of display on monitor panel is missing576
E-12 Monitor panel displays contents irrelevant to the model576
E-13 Fuel level monitor red lamp lights up while engine is running577
E-14 Engine cooling water temperature gauge does not indicate correctly578
E-15 Hydraulic oil temperature gauge does not display correctly579
E-16 Fuel gauge does not display correctly580
E-17 Swing lock monitor does not display correctly581
E-18 When the monitor switch is operated, no display appears582
E-19 Windshield wiper does not work584
E-20 Alarming buzzer cannot be cancelled586
E-21 “Boom RAISE” is not correctly displayed in monitor function587
E-22 “Boom LOWER” is not correctly displayed in monitor function588
E-23 “Arm DIGGING” is not correctly displayed in monitor function589
E-24 “Arm DUMPING” is not correctly displayed in monitor function590
E-25 “Bucket DIGGING” is not correctly displayed in monitor function591
E-26 “Bucket DUMPING” is not correctly displayed in monitor function592
E-27 “SWING” is not correctly displayed in monitor function594
E-28 “TRAVEL” is not correctly displayed in monitor function596
E-29 “Travel Differential Pressure” is not correctly displayed in monitor function598
E-30 “Service” is not correctly displayed in monitor function600
E-31 Air Conditioner does not work602
E-32 Travel alarm does not sound615
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)617
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS618
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE620
H-1 All work equipment lack power, or travel and swing speeds are slow621
H-2 Engine speed sharply drops or engine stalls622
H-3 No work equipment, travel or swing move623
H-4 Abnormal noise is heard from around hydraulic pump623
H-5 Auto-decelerator does not work624
H-6 Fine control mode does not function624
H-7 Boom moves slowly or lacks power625
H-8 Arm moves slowly or lacks power626
H-9 Bucket moves slowly or lacks power627
H-10 Work equipment does not move in its single operation627
H-11 Work equipment has a bit too fast hydraulic drift628
H-12 Work equipment has big time lag629
H-13 Other work equipment moves when relieving single circuit629
H-14 One-touch power max switch does not operate629
H-15 In compound operation, work equipment with larger load moves slowly630
H-16 In swing + boom RAISE operation, boom moves slowly630
H-17 In swing + travel, travel speed drops sharply630
H-18 Machine swerves in travel631
H-19 Machine travels slowly632
H-20 Machine cannot be easily steered or lacks power633
H-21 Travel speed does not shift, or it is too slow or fast634
H-22 Track shoe does not turn (on one side only)634
H-23 Machine does not swing635
H-24 Swing acceleration is poor, or swing speed is slow636
H-25 Excessive overrun when stopping swing637
H-26 There is big shock when stopping swing638
H-27 There is big abnormal noise caused when stopping swing638
H-28 Swing natural drift is too big639
TROUBLESHOOTING OF ENGINE (S-MODE)641
METHOD OF USING TROUBLESHOOTING CHARTS642
S-1 Starting performance is poor (Starting always takes time)646
S-2 Engine does not start648
(1) Engine does not turn648
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)649
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)650
S-3 Engine does not pick up smoothly (Follow-up is poor)651
S-4 Engine stops during operations652
S-5 Engine does not rotate smoothly (Hunting)653
S-6 Engine lacks output (or lacks power)654
S-7 Exhaust smoke is black (Incomplete combustion)655
S-8 Oil consumption is excessive (or exhaust smoke is blue)656
S-9 Oil becomes contaminated quickly657
S-10 Fuel consumption is excessive658
S-11 Oil is in cooling water, or water spurts back, or water level goes down659
S-12 Oil pressure monitor lights up (Drop in oil pressure)660
S-13 Oil level rises (Water, fuel in oil)661
S-14 Water temperature becomes too high (Overheating)662
S-15 Abnormal noise is made663
S-16 Vibration is excessive664
30 DISASSEMBLY AND ASSEMBLY665
HOW TO READ THIS MANUAL667
REMOVAL AND INSTALLATION OF ASSEMBLIES667
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES668
PRECAUTIONS WHEN PERFORMING OPERATION669
SPECIAL TOOL LIST671
SKETCHES OF SPECIAL TOOLS675
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY677
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY678
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL682
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL684
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL689
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY691
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY697
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY699
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLIES701
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY705
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY706
REMOVAL AND INSTALLATION OF SWING MOTOR, SWING MACHINERY ASSEMBLY716
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR, SWING MACHINERY ASSEMBLY717
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR, SWING MACHINERY ASSEMBLY724
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY733
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY734
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY735
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY738
REMOVAL AND INSTALLATION OF SPROCKET740
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY741
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY743
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY744
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY747
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY749
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY750
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY752
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY755
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY759
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT762
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY763
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY764
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY766
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY767
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY773
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY776
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY779
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY781
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY782
REMOVAL AND INSTALLATION OF OPERATOR’S CAB784
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)787
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY797
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY803
REMOVAL AND INSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY804
90 OTHERS805
HYDRAULIC CIRCUIT DIAGRAM807
PC300-7, PC300LC-7: Serial No 40001 – 45000 PC350-7, PC350LC-7: Serial No 20001 – 25000809
ELECTRICAL CIRCUIT DIAGRAM (1/4)809
ELECTRICAL CIRCUIT DIAGRAM (2/4)811
ELECTRICAL CIRCUIT DIAGRAM (3/4)813
ELECTRICAL CIRCUIT DIAGRAM (4/4)815
PC300-7, PC300LC-7: Serial No 45001 and up PC350-7, PC350LC-7: Serial No 25001 and up817
ELECTRICAL CIRCUIT DIAGRAM (1/4)817
ELECTRICAL CIRCUIT DIAGRAM (2/4)819
ELECTRICAL CIRCUIT DIAGRAM (3/4)821
ELECTRICAL CIRCUIT DIAGRAM (4/4)823

S.M 28/12/24