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Komatsu PC300-8, PC300LC-8, PC350-8 PC350LC-8 Excavator Shop Manual SEN01983-15 – PDF DOWNLOAD
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Komatsu PC300-8, PC300LC-8, PC350-8 PC350LC-8 Excavator Shop Manual
SERIAL NUMBERS:
PC300- 60001 and up
PC300LC-60001 and up
PC350- 60001 and up
PC350LC-60001 and up
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Description
Komatsu PC300-8, PC300LC-8, PC350-8 PC350LC-8 Excavator Shop Manual
FILE DETAILS:
Komatsu PC300-8, PC300LC-8, PC350-8 PC350LC-8 Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC300-8, PC300LC-8, PC350-8, PC350LC-8
Serial Number: 60001 and up
Book Code: SEN01983-15
Language: English
Pages: 1035
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC300-8, PC300LC-8, PC350-8 PC350LC-8 Excavator Shop Manual
How to read the shop manual:
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):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC300-8, PC300LC-8, PC350-8 PC350LC-8 Excavator Shop Manual
COVER ....................................................................................... 1 00 Index and foreword........................................................................ 0 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............................................................................. 0 Specification and technical data......................................................... 57 Specification dimension drawings..................................................... 58 Dimensions....................................................................... 58 Working ranges................................................................... 59 Specifications....................................................................... 60 Weight table......................................................................... 66 Table of fuel, coolant and lubricants................................................ 68 10 Structure, function and maintenance standard.............................................. 0 Engine and cooling system................................................................ 71 Engine related parts................................................................. 72 Radiator, oil cooler and aftercooler................................................. 73 Power train.............................................................................. 75 Power train.......................................................................... 76 Swing circle......................................................................... 77 Swing machinery...................................................................... 78 Final drive.......................................................................... 80 Sprocket............................................................................. 82 Undercarriage and frame.................................................................. 85 Track frame and recoil spring........................................................ 86 Idler................................................................................ 88 Carrier roller....................................................................... 90 Track roller......................................................................... 91 Track shoe........................................................................... 92 Hydraulic system, Part 1................................................................. 97 Hydraulic equipment layout drawing................................................... 98 Hydraulic tank and filter............................................................ 100 Hydraulic pump....................................................................... 102 Hydraulic system, Part 2................................................................. 127 Control valve........................................................................ 128 CLSS................................................................................. 140 Functions and operation by valve..................................................... 144 Merge-divider valve.................................................................. 159 Attachment circuit selector valve.................................................... 184 Hydraulic drift prevention valve..................................................... 186 Hydraulic system, Part 3................................................................. 193 Valve control........................................................................ 194 PPC valve............................................................................ 196 Solenoid valve....................................................................... 218 PPC accumulator...................................................................... 220 Return oil filter.................................................................... 221 Center swivel joint.................................................................. 222 Travel motor......................................................................... 223 Swing motor.......................................................................... 235 Hydraulic cylinder................................................................... 244 Work equipment........................................................................... 247 Work equipment....................................................................... 248 Dimensions of components............................................................. 250 Cab and its attachments.................................................................. 255 Air conditioner piping............................................................... 256 Electrical system........................................................................ 259 Engine control....................................................................... 260 Electronic control system............................................................ 269 Monitor system....................................................................... 294 Sensor............................................................................... 321 KOMTRAX system....................................................................... 324 20 Standard value table...................................................................... 0 Standard service value table............................................................. 327 Standard value table for engine related parts........................................ 328 Standard value table for chassis related parts....................................... 329 30 Testing and adjusting..................................................................... 0 Testing and adjusting, Part 1............................................................ 341 Tools for testing, adjusting and troubleshooting..................................... 343 Sketches of special tools............................................................ 347 Testing engine speed................................................................. 348 Testing air boost pressure........................................................... 349 Testing exhaust gas color............................................................ 350 Adjusting valve clearance............................................................ 352 Testing compression pressure......................................................... 354 Testing blow-by pressure............................................................. 358 Testing engine oil pressure.......................................................... 359 Testing fuel pressure................................................................ 360 Handling during cylinder cut-out operation........................................... 365 Handling during no injection cranking operation...................................... 365 Testing fuel return rate and leakage................................................. 366 Bleeding air from fuel circuit....................................................... 368 Checking fuel circuit for leakage.................................................... 369 Testing and adjusting air compressor belt tension.................................... 370 Replacing fan belt................................................................... 371 Replacing alternator belt............................................................ 372 Testing clearance in swing circle bearings........................................... 373 Testing and adjusting track shoe tension............................................. 374 Testing and adjusting oil pressure in work equipment, swing and travel circuit....... 375 Testing and adjusting control circuit oil pressure................................... 379 Testing and adjusting pump PC control circuit oil pressure........................... 380 Testing and adjusting pump LS control circuit oil pressure........................... 383 Testing solenoid valve output pressure............................................... 388 Testing PPC valve output pressure.................................................... 392 Adjusting play of work equipment and swing PPC valves................................ 393 Inspecting locations of hydraulic drift of work equipment............................ 394 Releasing remaining pressure in hydraulic circuit.................................... 396 Testing oil leakage amount........................................................... 396 Bleeding air from various parts...................................................... 399 Diode inspection procedures.......................................................... 401 Testing and adjusting, Part 2............................................................ 407 Special functions of machine monitor................................................. 408 Testing and adjusting, Part 3............................................................ 465 Handling voltage circuit of engine controller........................................ 466 Preparation work for troubleshooting of electrical system............................ 467 Procedure for testing diodes......................................................... 471 Pm clinic service.................................................................... 472 40 Troubleshooting........................................................................... 0 Failure code table and fuse locations.................................................... 479 Failure codes table.................................................................. 480 Fuse locations....................................................................... 483 General information on troubleshooting................................................... 489 Points to remember when troubleshooting.............................................. 490 Sequence of events in troubleshooting................................................ 491 Checks before troubleshooting........................................................ 492 Classification and troubleshooting steps............................................. 493 Information in troubleshooting table................................................. 494 Connection table for connector pin numbers........................................... 499 T- branch box and T- branch adapter table............................................ 535 Troubleshooting by failure code (Display of code), Part 1................................ 539 Failure code [989L00] Engine Controller Lock Caution 1............................... 541 Failure code [989M00] Engine Controller Lock Caution 2............................... 541 Failure code [989N00] Engine Controller Lock Caution 3............................... 542 Failure code [AA10NX] Air cleaner Clogging........................................... 544 Failure code [AB00KE] Charge Voltage Low............................................. 546 Failure code [B@BAZG] Eng Oil Press. Low............................................. 548 Failure code [B@BAZK] Eng Oil Level Low.............................................. 550 Failure code [B@BCNS] Eng. Water Overheat............................................ 552 Failure code [B@BCZK] Eng Water Level Low............................................ 554 Failure code [B@HANS] Hydr Oil Overheat.............................................. 556 Failure code [CA111] EMC Critical Internal Failure................................... 557 Failure code [CA115] Eng Ne and Bkup Speed Sens Error................................ 557 Failure code [CA122] Chg Air Press Sensor High Error................................. 558 Failure code [CA123] Chg Air Press Sensor Low Error.................................. 560 Failure code [CA131] Throttle Sensor High Error...................................... 562 Failure code [CA132] Throttle Sensor Low Error....................................... 564 Failure code [CA144] Coolant Temp Sens High Error.................................... 566 Failure code [CA145] Coolant Temp Sens Low Error..................................... 568 Failure code [CA153] Chg Air Temp Sensor High Error.................................. 570 Failure code [CA154] Chg Air Temp Sensor Low Error................................... 572 Failure code [CA155] Chg Air Temp High Speed Derate.................................. 574 Failure code [CA187] Sens Supply 2 Volt Low Error.................................... 576 Failure code [CA221] Ambient Press Sens High Error................................... 578 Failure code [CA222] Ambient Press Sens Low Error.................................... 580 Failure code [CA227] Sens Supply 2 Volt High Error................................... 582 Failure code [CA234] Eng Overspeed................................................... 583 Failure code [CA238] Ne Speed Sens Supply Volt Error................................. 584 Failure code [CA271] IMV/PCV1 Short Error............................................ 585 Failure code [CA272] IMV/PCV1 Open Error............................................. 586 Failure code [CA281] Pump Press Balance Error........................................ 588 Failure code [CA322] Inj #1 (L/B#1) Open/Short Error................................. 589 Failure code [CA323] Inj #5 (L/B#5) Open/Short Error................................. 591 Failure code [CA324] Inj #3 (L/B#3) Open/Short Error................................. 593 Failure code [CA325] Inj #6 (L/B#6) Open/Short Error................................. 595 Failure code [CA331] Inj #2 (L/B#2) Open/Short Error................................. 597 Failure code [CA332] Inj #4 (L/B#4) Open/Short Error................................. 599 Troubleshooting by failure code (Display of code), Part 2................................ 603 Failure code [CA342] Calibration Code Incompatibility................................ 605 Failure code [CA351] Injectors Drive Circuit Error................................... 606 Failure code [CA352] Sens Supply 1 Volt Low Error.................................... 608 Failure code [CA386] Sens Supply 1 Volt High Error................................... 610 Failure code [CA428] Water in Fuel Sensor High Error................................. 612 Failure code [CA429] Water in Fuel Sensor Low Error.................................. 614 Failure code [CA435] Eng Oil Press Sw Error.......................................... 616 Failure code [CA441] Battery Voltage Low Error....................................... 618 Failure code [CA442] Battery Voltage High Error...................................... 620 Failure code [CA449] Rail Press Very High Error...................................... 622 Failure code [CA451] Rail Press Sensor High Error.................................... 626 Failure code [CA452] Rail Press Sensor Low Error..................................... 628 Failure code [CA488] Chg Air Temp High Torque Derate................................. 630 Failure code [CA553] Rail Press High Error........................................... 630 Failure code [CA559] Rail Press Low Error............................................ 632 Failure code [CA689] Eng Ne Speed Sensor Error....................................... 634 Failure code [CA731] Eng Bkup Speed Sens Phase Error................................. 636 Failure code [CA757] All Persistent Data Lost Error.................................. 638 Failure code [CA778] Eng Bkup Speed Sensor Error..................................... 640 Failure code [CA1633] KOMNET Datalink Timeout Error.................................. 642 Failure code [CA2185] Throt Sens Sup Volt High Error................................. 644 Failure code [CA2186] Throt Sens Sup Volt Low Error.................................. 645 Failure code [CA2249] Rail Press Very Low Error...................................... 646 Failure code [CA2265] Fuel Feed Pump Open Error...................................... 648 Failure code [CA2266] Fuel Feed Pump Short Error..................................... 650 Failure code [CA2311] IMV Solenoid Error............................................. 652 Failure code [CA2555] Grid Htr Relay Volt Low Error.................................. 654 Failure code [CA2556] Grid Htr Relay Volt High Error................................. 656 Failure code [D110KB] Battery Relay Drive S/C........................................ 658 Failure code [D19JKZ] Personal Code Relay Abnormality................................ 660 Failure code [D862KA] GPS Antenna Discon............................................. 662 Failure code [DA22KK] Pump Solenoid Power Low Error.................................. 663 Failure code [DA25KP] 5V sensor 1 power abnormality.................................. 665 Failure code [DA29KQ] Model Selection Abnormality.................................... 668 Failure code [DA2RMC] Pump Comm. Abnormality......................................... 670 Failure code [DAF8KB] Short circuit in camera power supply........................... 672 Failure code [DAFGMC] GPS Module Error............................................... 674 Troubleshooting by failure code (Display of code), Part 3................................ 677 Failure code [DAFRMC] CAN discon (Monitor detected).................................. 680 Failure code [DGH2KB] Hydr Oil Sensor Short.......................................... 682 Failure code [DHPAMA] F Pump Press Sensor Abnormality................................ 684 Failure code [DHPBMA] R Pump Press Sensor Abnormality................................ 686 Failure code [DHS3MA] Arm Curl PPC Sensor Abnormality................................ 688 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality....................... 690 Failure code [DHX1MA] Overload Sensor Abnormality (Analog)........................... 692 Failure code [DW43KA] Travel Speed Sol. Open Circuit................................. 694 Failure code [DW43KB] Travel Speed Sol. Short Circuit................................ 696 Failure code [DW45KA] Swing Brake Sol. Open Circuit.................................. 698 Failure code [DW45KB] Swing Brake Sol. Short Circuit................................. 702 Failure code [DW91KA] Travel Junction Sol. Open Circuit.............................. 704 Failure code [DW91KB] Travel Junction Sol. Short Circuit............................. 706 Failure code [DWA2KA] Attachment Sol Open Circuit.................................... 708 Failure code [DWA2KB] Attachment Sol Short Circuit................................... 709 Failure code [DWJ0KA] Merge-divider Sol. Open Circuit................................ 710 Failure code [DWJ0KB] Merge-divider Sol. Short Circuit............................... 712 Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit............................... 714 Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit.............................. 716 Failure code [DXA0KA] PC-EPC Sol. Open Circuit....................................... 718 Failure code [DXA0KB] PC-EPC Sol. Short Circuit...................................... 720 Failure code [DXE0KA] LS-EPC Sol. Open Circuit....................................... 722 Failure code [DXE0KB] LS-EPC Sol. Short Circuit...................................... 724 Failure code [DXE4KA] Service Current EPC Open Circuit............................... 726 Failure code [DXE4KB] Service Current EPC Short Circuit.............................. 727 Failure code [DY20KA] Wiper Working Abnormality...................................... 728 Failure code [DY20MA] Wiper Parking Abnormality...................................... 730 Failure code [DY2CKA] Washer Drive Open Circuit...................................... 732 Failure code [DY2CKB] Washer Drive Short Circuit..................................... 734 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit................................ 736 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit................................ 738 Troubleshooting of electrical system (E-mode)............................................ 741 Before carrying out troubleshooting of electrical system............................. 744 Information contained in troubleshooting table....................................... 746 E-1 Engine does not start............................................................ 747 E-2 Auto-decelerator does not operate................................................ 750 E-3 Automatic warming-up system does not operate..................................... 752 E-4 Preheater does not operate....................................................... 754 E-5 All work equipment, swing, and travel mechanism do not move...................... 756 E-6 Power maximizing function does not operate....................................... 758 E-7 Machine monitor does not display at all.......................................... 760 E-8 Machine monitor does not display some items...................................... 762 E-9 Contents of display by machine monitor are different from applicable machine..... 762 E-10 Fuel level monitor was lighted in red while engine running...................... 763 E-11 Engine coolant temperature gauge does not indicate normally..................... 764 E-12 Hydraulic oil temperature gauge does not indicate normally...................... 766 E-13 Fuel level gauge does not indicate normally..................................... 767 E-14 Swing lock monitor does not indicate normally................................... 768 E-15 When monitor switch is operated, monitor displays nothing....................... 770 E-16 Windshield wiper and window washer do not operate............................... 772 E-17 Machine push-up function does not operate normally.............................. 776 E-18 Monitoring function fails to display “boom raise” normally...................... 778 E-19 Monitoring function fails to display “boom lower” normally...................... 780 E-20 Monitoring function fails to display “arm IN” normally.......................... 782 E-21 Monitoring function fails to display “arm OUT” normally......................... 784 E-22 Monitoring function fails to display “bucket CURL” normally..................... 786 E-23 Monitoring function fails to display “bucket DUMP” normally..................... 788 E-24 Monitoring function fails to display “swing” normally........................... 790 E-25 Monitoring function fails to display “travel” normally.......................... 792 E-26 Monitoring function fails to display “travel differential pressure” normally.... 794 E-27 Monitoring function fails to display “service” normally......................... 796 E-28 KOMTRAX system does not operate normally........................................ 798 E-29 Air conditioner does not operate................................................ 800 E-30 Travel alarm does not sound or does not stop sounding........................... 802 E-31 Horn does not sound............................................................. 804 Troubleshooting of hydraulic and mechanical system (H-mode).............................. 807 System chart for hydraulic and mechanical system..................................... 810 Information contained in troubleshooting table....................................... 812 H-1 All work equipment lack power, or travel and swing speeds are slow............... 814 H-2 Engine speed sharply drops or engine stalls...................................... 816 H-3 No work equipment, swing or travel move.......................................... 817 H-4 Abnormal noise is heard from around hydraulic pump............................... 817 H-5 Auto-decelerator does not work................................................... 818 H-6 Fine control mode does not function or responds slow............................. 818 H-7 Boom moves slowly or lacks power................................................. 819 H-8 Arm moves slowly or lacks power.................................................. 820 H-9 Bucket moves slowly or lacks power............................................... 821 H-10 Work equipment does not move in its single operation............................ 821 H-11 Work equipment has a bit too fast hydraulic drift............................... 822 H-12 Work equipment has big time lag................................................. 824 H-13 Other work equipment moves when relieving single circuit........................ 824 H-14 Power max. switch does not operate.............................................. 825 H-15 In compound operation, work equipment with larger load moves slowly............. 825 H-16 In swing + boom RAISE operation, boom moves slowly.............................. 826 H-17 In swing + travel operation, travel speed drops sharply......................... 826 H-18 Machine swerves in travel....................................................... 827 H-19 Machine travels slowly.......................................................... 828 H-20 Machine cannot be easily steered or lacks power................................. 829 H-21 Travel speed does not shift, or it is too slow or fast.......................... 830 H-22 Track shoe does not turn (on one side only)..................................... 831 H-23 Machine does not swing.......................................................... 832 H-24 Swing acceleration is poor, or swing speed is slow.............................. 834 H-25 Excessive overrun when stopping swing........................................... 836 H-26 There is big shock when stopping swing.......................................... 837 H-27 Large sound is made when upper structure stops swinging......................... 837 H-28 Swing hydraulic drift is too big................................................ 838 Troubleshooting of engine (S-mode)....................................................... 841 Method of using troubleshooting chart................................................ 843 S-1 Starting performance is poor..................................................... 846 S-2 Engine does not start............................................................ 847 S-3 Engine does not pick up smoothly................................................. 850 S-4 Engine stops during operations................................................... 851 S-5 Engine does not rotate smoothly.................................................. 852 S-6 Engine lacks output (or lacks power)............................................. 853 S-7 Exhaust smoke is black (incomplete combustion)................................... 854 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................... 855 S-9 Oil becomes contaminated quickly................................................. 856 S-10 Fuel consumption is excessive................................................... 857 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)........... 858 S-12 Oil pressure drops.............................................................. 859 S-13 Oil level rises (Entry of coolant or fuel)...................................... 860 S-14 Coolant temperature becomes too high (overheating).............................. 861 S-15 Abnormal noise is made.......................................................... 862 S-16 Vibration is excessive.......................................................... 863 50 Disassembly and assembly.................................................................. 0 General information on disassembly and assembly.......................................... 865 How to read this manual.............................................................. 866 Coating materials list............................................................... 868 Special tools list................................................................... 871 Sketches of special tools............................................................ 874 Engine and cooling system................................................................ 879 Removal and installation of fuel supply pump assembly................................ 880 Removal and installation of engine front seal........................................ 883 Removal and installation of engine rear seal......................................... 886 Removal and installation of cylinder head assembly................................... 891 Removal and installation of radiator assembly........................................ 904 Removal and installation of hydraulic oil cooler assembly............................ 906 Removal and installation of aftercooler assembly..................................... 908 Removal and installation of aftercooler assembly..................................... 909 Power train.............................................................................. 915 Removal and installation of final drive assembly..................................... 916 Disassembly and assembly of final drive assembly..................................... 917 Removal and installation of swing motor and swing machinery assembly................. 925 Disassembly and assembly of swing motor and swing machinery assembly................. 926 Removal and installation of swing circle assembly.................................... 933 Undercarriage and frame.................................................................. 935 Disassembly and assembly of carrier roller........................................... 936 Disassembly and assembly of track roller assembly.................................... 937 Disassembly and assembly of idler assembly........................................... 938 Disassembly and assembly of recoil spring............................................ 941 Removal and installation of sprocket................................................. 943 Expansion and installation of track shoe assembly.................................... 944 Removal and installation of revolving frame assembly................................. 946 Removal and installation of counterweight assembly................................... 948 Hydraulic system......................................................................... 953 Removal and installation of center swivel joint assembly............................. 954 Disassembly and assembly of center swivel joint assembly............................. 956 Removal and installation of hydraulic tank assembly.................................. 957 Removal and installation of control valve assembly................................... 959 Disassembly and assembly of control valve assembly................................... 962 Removal and installation of hydraulic pump assembly.................................. 963 Removal and installation of oil seal in hydraulic pump input shaft................... 965 Disassembly and assembly of work equipment PPC valve assembly........................ 966 Disassembly and assembly of travel PPC valve assembly................................ 968 Disassembly and assembly of hydraulic cylinder assembly.............................. 971 Work equipment........................................................................... 977 Removal and installation of work equipment assembly.................................. 978 Cab and its attachments.................................................................. 983 Removal and installation of operator's cab assembly.................................. 984 Removal and installation of operator cab glass (stuck glass)......................... 987 Removal and installation of front window assembly.................................... 997 Removal and installation of floor frame assembly.....................................1004 Electrical system........................................................................1009 Removal and installation of air conditioner unit assembly............................1010 Removal and installation of KOMTRAX communication modem assembly.....................1013 Removal and installation of monitor assembly.........................................1014 Removal and installation of pump controller assembly.................................1016 Removal and installation of engine controller........................................1018 90 Diagrams and drawings..................................................................... 0 Hydraulic diagrams and drawings..........................................................1021 Hydraulic circuit diagram............................................................1023 Electrical diagrams and drawings.........................................................1026 Electrical circuit diagram...........................................................1028 Connector list and sterogram.........................................................1033
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