Komatsu PC300-7E0 PC300LC-7E0 PC350-7E0 PC350LC-7E0 Excavator Shop Manual SEN03537-05

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Komatsu PC300-7E0 PC300LC-7E0 PC350-7E0 PC350LC-7E0 Excavator Shop Manual SEN03537-05 – PDF DOWNLOAD 

FILE DETAILS:

Komatsu PC300-7E0 PC300LC-7E0 PC350-7E0 PC350LC-7E0 Excavator Shop Manual SEN03537-05 – PDF DOWNLOAD 

Language : English
Pages : 974
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC300-7E0 PC300LC-7E0 PC350-7E0 PC350LC-7E0 Excavator Shop Manual SEN03537-05 – PDF DOWNLOAD 

SERIAL NUMBERS
PC300,300LC- 50001-50216
PC300,300LC- 55001 and up
PC350,350LC- 30001-30093
PC350,350LC- 55001 and up

How to read the shop manual 1
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu PC300-7E0 PC300LC-7E0 PC350-7E0 PC350LC-7E0 Excavator Shop Manual SEN03537-05 – PDF DOWNLOAD 

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines 34
How to read electric wire code 37
Precautions when carrying out operation 40
Method of disassembling and connecting push-pull type coupler 43
Standard tightening torque table 46
Conversion table 50
01 Specification 57
Specification and technical data 57
Specification dimension drawings 58
Specifications 60
Weight table 66
Table of fuel, coolant and lubricants 68
10 Structure, function and maintenance standard 71
Engine and cooling system 71
Engine related parts 72
Radiator, oil cooler and aftercooler 73
Power train 75
Power train 76
Final drive 78
Sprocket 80
Swing machinery 82
Swing circle 84
Undercarriage and frame 87
Track frame and recoil spring 88
Idler 90
Carrier roller 92
Track roller 93
Track shoe 94
Hydraulic system, Part 1 99
Hydraulic equipment layout drawing 100
Hydraulic tank and filter 102
Hydraulic pump 104
Hydraulic system, Part 2 129
Control valve 130
CLSS 142
Functions and operation by valve 146
Merge-divider valve 161
Attachment circuit selector valve 186
Hydraulic drift prevention valve 188
Hydraulic system, Part 3 195
Valve control 196
PPC valve 197
Solenoid valve 213
PPC accumulator 215
Return oil filter 216
Center swivel joint 217
Travel motor 218
Swing motor 230
Hydraulic cylinder 239
Work equipment 243
Work equipment 244
Dimensions of components 246
Cab and its attachments 251
Air conditioner piping 252
Electrical system 255
Engine control 256
Electronic control system 265
Monitor system 290
Sensor 308
KOMTRAX system 311
20 Standard value table 315
Standard service value table 315
Standard value table for engine related parts 316
Standard value table for chassis related parts 317
30 Testing and adjusting 329
Testing and adjusting, Part 1 329
Tools for testing, adjusting and troubleshooting 331
Sketches of special tools 335
Measuring engine speed 336
Measuring air boost pressure 337
Measuring exhaust gas color 338
Adjusting valve clearance 340
Measuring compression pressure 342
Measuring blow-by pressure 346
Measuring engine oil pressure 347
Measuring fuel pressure 348
Handling during cylinder cut-out operation 353
Handling during no injection cranking operation 353
Measuring fuel return rate and leakage 354
Bleeding air from fuel circuit 356
Checking fuel circuit for leakage 357
Testing and adjusting air compressor belt tension 358
Replacement of fan belt 359
Replacement of alternator belt 360
Measuring clearance in swing circle bearings 361
Testing and adjusting track shoe tension 362
Testing and adjusting oil pressure in work equipment, swing and travel circuit 363
Testing and adjusting control circuit oil pressure 367
Testing and adjusting pump PC control circuit oil pressure 368
Testing and adjusting pump LS control circuit oil pressure 371
Measuring solenoid valve output pressure 376
Measuring PPC valve output pressure 380
Adjusting play of work equipment and swing PPC valves 381
Inspecting locations of hydraulic drift of work equipment 382
Releasing remaining pressure in hydraulic circuit 384
Measuring oil leakage amount 385
Bleeding air from various parts 387
Testing and adjusting, Part 2 391
Special functions of machine monitor 392
Testing and adjusting, Part 3 421
Procedure for turning on KOMTRAX terminal 422
Indication by KOMTRAX terminal lamps 425
Handling voltage circuit of engine controller 428
Preparation work for troubleshooting of electrical system 429
Procedure for testing diodes 433
Pm clinic service 434
40 Troubleshooting 441
Failure code table and fuse locations 441
Failure codes table 442
Before carrying out troubleshooting when failure code is displayed 446
General information on troubleshooting 451
Points to remember when troubleshooting 452
Sequence of events in troubleshooting 453
Checks before troubleshooting 454
Classification and troubleshooting steps 455
Information in troubleshooting table 456
Connection table for connector pin numbers 461
T- branch box and T- branch adapter table 497
Troubleshooting by failure code (Display of code), Part 1 501
Failure code [AA10NX] Air cleaner Clogging 504
Failure code [AB00KE] Charge Voltage Low 506
Failure code [B@BAZG] Eng Oil Press Low 508
Failure code [B@BAZK] Eng Oil Level Low 510
Failure code [B@BCNS] Eng Water Overheat 512
Failure code [B@BCZK] Eng Water Level Low 514
Failure code [B@HANS] Hydr Oil Overheat 516
Failure code [CA111] EMC Critical Internal Failure 518
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 519
Failure code [CA122] Chg Air Press Sensor High Error 520
Failure code [CA123] Chg Air Press Sensor Low Error 522
Failure code [CA131] Throttle Sensor High Error 524
Failure code [CA132] Throttle Sensor Low Error 526
Failure code [CA144] Coolant Temp Sens High Error 528
Failure code [CA145] Coolant Temp Sens Low Error 530
Failure code [CA153] Chg Air Temp Sensor High Error 532
Failure code [CA154] Chg Air Temp Sensor Low Error 534
Failure code [CA155] Chg Air Temp High Speed Derate 536
Failure code [CA187] Sens Supply 2 Volt Low Error 538
Failure code [CA221] Ambient Press Sens High Error 540
Failure code [CA222] Ambient Press Sens Low Error 542
Failure code [CA227] Sens Supply 2 Volt High Error 544
Failure code [CA234] Eng Overspeed 545
Failure code [CA238] Ne Speed Sens Supply Volt Error 546
Failure code [CA271] IMV/PCV1 Short Error 547
Failure code [CA272] IMV/PCV1 Open Error 548
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error 550
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error 552
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error 554
Failure code [CA325] Inj #6 (L/B#6) Open/Short Error 556
Failure code [CA331] Inj #2 (L/B#2) Open/Short Error 558
Failure code [CA332] Inj #4 (L/B#4) Open/Short Error 560
Troubleshooting by failure code (Display of code), Part 2 563
Failure code [CA342] Calibration Code Incompatibility 565
Failure code [CA351] Injectors Drive Circuit Error 566
Failure code [CA352] Sens Supply 1 Volt Low Error 568
Failure code [CA386] Sens Supply 1 Volt High Error 570
Failure code [CA428] Water in Fuel Sensor High Error 572
Failure code [CA429] Water in Fuel Sensor Low Error 574
Failure code [CA435] Eng Oil Press Sw Error 576
Failure code [CA441] Battery Voltage Low Error 578
Failure code [CA442] Battery Voltage High Error 580
Failure code [CA449] Rail Press Very High Error 582
Failure code [CA451] Rail Press Sensor High Error 586
Failure code [CA452] Rail Press Sensor Low Error 588
Failure code [CA553] Rail Press High Error 590
Failure code [CA559] Rail Press Low Error 591
Failure code [CA689] Eng Ne Speed Sensor Error 593
Failure code [CA731] Eng Bkup Speed Sens Phase Error 595
Failure code [CA757] All Persistent Data Lost Error 596
Failure code [CA778] Eng Bkup Speed Sensor Error 598
Failure code [CA1633] KOMNET Datalink Timeout Error 600
Failure code [CA2185] Throt Sens Sup Volt High Error 602
Failure code [CA2186] Throt Sens Sup Volt Low Error 603
Failure code [CA2249] Rail Press Very Low Error 604
Failure code [CA2265] Fuel Feed Pump Open Error 606
Failure code [CA2266] Fuel Feed Pump Short Error 608
Failure code [CA2311] IMV Solenoid Error 610
Failure code [CA2555] Grid Htr Relay Volt Low Error 612
Failure code [CA2556] Grid Htr Relay Volt High Error 614
Failure code [D110KB] Battery Relay Drive Short Circuit 616
Failure code [D196KA] Service Return Relay Disc 618
Failure code [D196KB] Service Return Relay S/C 620
Failure code [DA25KP] Press Sensor Power Abnormality 622
Failure code [DA2RMC] Pump Comm Abnormality 624
Failure code [DA2SKQ] Model Selection Abnormality 626
Troubleshooting by failure code (Display of code), Part 3 629
Failure code [DAFRMC] Monitor Comm Abnormality 632
Failure code [DHPAMA] F Pump Press Sensor Abnormality 634
Failure code [DGH2KB] Hydr Oil Sensor Short Circuit 636
Failure code [DHPBMA] R Pump Press Sensor Abnormality 638
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 640
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 642
Failure code [DW43KA] Travel Speed Sol Open Circuit 644
Failure code [DW43KB] Travel Speed Sol Short Circuit 646
Failure code [DW45KA] Swing Brake Sol Open Circuit 648
Failure code [DW45KB] Swing Brake Sol Short Circuit 652
Failure code [DW91KA] Travel Junction Sol Open Circuit 654
Failure code [DW91KB] Travel Junction Sol Short Circuit 656
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 658
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 660
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 662
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 664
Failure code [DXA0KA] PC-EPC Sol Open Circuit 666
Failure code [DXA0KB] PC-EPC Sol Short Circuit 668
Failure code [DXE0KA] LS-EPC Sol Open Circuit 670
Failure code [DXE0KB] LS-EPC Sol Short Circuit 672
Failure code [DXE4KA] Service Current EPC Open Circuit 674
Failure code [DXE4KB] Service Current EPC Short Circuit 675
Failure code [DY20KA] Wiper Working Abnormality 676
Failure code [DY20MA] Wiper Parking Abnormality 678
Failure code [DY2CKB] Washer Drive Short Circuit 680
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 682
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 684
Troubleshooting of electrical system (E-mode) 687
Before carrying out troubleshooting of electrical system 690
Information contained in troubleshooting table 692
E-1 Engine does not start 693
E-2 Auto-decelerator does not operate 696
E-3 Automatic warming-up system does not operate 698
E-4 Preheater does not operate 700
E-5 All work equipment, swing, and travel mechanism do not move 702
E-6 Power maximizing function does not operate 704
E-7 Machine monitor does not display at all 706
E-8 Machine monitor does not display some items 708
E-9 Contents of display by machine monitor are different from applicable machine 708
E-10 Fuel level monitor was lighted in red while engine running 709
E-11 Engine coolant temperature gauge does not indicate normally 710
E-12 Hydraulic oil temperature gauge does not indicate normally 712
E-13 Fuel level gauge does not indicate normally 713
E-14 Swing lock monitor does not indicate normally 714
E-15 When monitor switch is operated, monitor displays nothing 716
E-16 Windshield wiper and window washer do not operate 718
E-17 Machine push-up function does not operate normally 722
E-18 Monitoring function fails to display “boom raise” normally 724
E-19 Monitoring function fails to display “boom lower” normally 726
E-20 Monitoring function fails to display “arm IN” normally 728
E-21 Monitoring function fails to display “arm OUT” normally 730
E-22 Monitoring function fails to display “bucket CURL” normally 732
E-23 Monitoring function fails to display “bucket DUMP” normally 734
E-24 Monitoring function fails to display “swing” normally 736
E-25 Monitoring function fails to display “travel” normally 738
E-26 Monitoring function fails to display “travel differential pressure” normally 740
E-27 Monitoring function fails to display “service” normally 742
E-28 KOMTRAX system does not operate normally 744
E-29 Air conditioner does not operate 746
E-30 Travel alarm does not sound or does not stop sounding 748
E-31 Horn does not sound 750
Troubleshooting of hydraulic and mechanical system (H-mode) 753
System chart for hydraulic and mechanical system 756
Information contained in troubleshooting table 758
H-1 All work equipment lack power, or travel and swing speeds are slow 760
H-2 Engine speed sharply drops or engine stalls 762
H-3 No work equipment, swing or travel move 763
H-4 Abnormal noise is heard from around hydraulic pump 763
H-5 Auto-decelerator does not work 764
H-6 Fine control mode does not function or responds slow 764
H-7 Boom moves slowly or lacks power 765
H-8 Arm moves slowly or lacks power 766
H-9 Bucket moves slowly or lacks power 767
H-10 Work equipment does not move in its single operation 767
H-11 Work equipment has a bit too fast hydraulic drift 768
H-12 Work equipment has big time lag 770
H-13 Other work equipment moves when relieving single circuit 770
H-14 Power max switch does not operate 771
H-15 Machine push-up function does not operate 771
H-16 In compound operation, work equipment with larger load moves slowly 772
H-17 In swing + boom RAISE operation, boom moves slowly 772
H-18 In swing + travel operation, travel speed drops sharply 772
H-19 Machine swerves in travel 773
H-20 Machine travels slowly 774
H-21 Machine cannot be easily steered or lacks power 775
H-22 Travel speed does not shift, or it is too slow or fast 776
H-23 Track shoe does not turn (on one side only) 777
H-24 Machine does not swing 778
H-25 Swing acceleration is poor, or swing speed is slow 780
H-26 Excessive overrun when stopping swing 782
H-27 There is big shock when stopping swing 783
H-28 Large sound is made when upper structure stops swinging 783
H-29 Swing hydraulic drift is too big 784
Troubleshooting of engine (S-mode) 787
Method of using troubleshooting chart 789
S-1 Starting performance is poor 792
S-2 Engine does not start 793
S-3 Engine does not pick up smoothly 796
S-4 Engine stops during operations 797
S-5 Engine does not rotate smoothly 798
S-6 Engine lacks output (or lacks power) 799
S-7 Exhaust smoke is black (incomplete combustion) 800
S-8 Oil consumption is excessive (or exhaust smoke is blue) 801
S-9 Oil becomes contaminated quickly 802
S-10 Fuel consumption is excessive 803
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 804
S-12 Oil pressure drops 805
S-13 Oil level rises (Entry of coolant or fuel) 806
S-14 Coolant temperature becomes too high (overheating) 807
S-15 Abnormal noise is made 808
S-16 Vibration is excessive 809
50 Disassembly and assembly 811
General information on disassembly and assembly 811
How to read this manual 812
Coating materials list 814
Special tools list 817
Sketches of special tools 821
Engine and cooling system 825
Removal and installation of fuel supply pump assembly 826
Removal and installation of engine front seal 829
Removal and installation of engine rear seal 832
Removal and installation of cylinder head assembly 837
Removal and installation of radiator assembly 850
Removal and installation of hydraulic oil cooler assembly 852
Removal and installation of aftercooler assembly 854
Removal and installation of engine and hydraulic pump assembly 855
Power train 861
Removal and installation of final drive assembly 862
Disassembly and assembly of final drive assembly 863
Removal and installation of swing motor and swing machinery assembly 871
Disassembly and assembly of swing motor and swing machinery assembly 872
Removal and installation of swing circle assembly 879
Undercarriage and frame 881
Disassembly and assembly of carrier roller 882
Disassembly and assembly of track roller assembly 883
Disassembly and assembly of idler assembly 884
Disassembly and assembly of recoil spring 887
Removal and installation of sprocket 889
Expansion and installation of track shoe assembly 890
Removal and installation of revolving frame assembly 891
Removal and installation of counterweight assembly 893
Hydraulic system 895
Removal and installation of center swivel joint assembly 896
Disassembly and assembly of center swivel joint assembly 898
Removal and installation of hydraulic tank assembly 899
Removal and installation of control valve assembly 901
Disassembly and assembly of control valve assembly 904
Removal and installation of hydraulic pump assembly 906
Removal and installation of oil seal in hydraulic pump input shaft 908
Disassembly and assembly of work equipment PPC valve assembly 909
Disassembly and assembly of travel PPC valve assembly 911
Disassembly and assembly of hydraulic cylinder assembly 914
Work equipment 921
Removal and installation of work equipment assembly 922
Cab and its attachments 927
Removal and installation of operator’s cab assembly 928
Removal and installation of operator’s cab glass (stuck glass) 931
Removal and installation of front window assembly 940
Electrical system 947
Removal and installation of assembly 948
Removal and installation of machine monitor 950
Removal and installation of pump controller 950
Removal and installation of KOMTRAX terminal 951
Removal and installation of engine controller 951
90 Diagrams and drawings 953
Hydraulic diagrams and drawings 953
Hydraulic circuit diagram 955
Electrical diagrams and drawings 959
Electrical circuit diagram 961
Connector list and stereogram 971

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