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Komatsu PC300-8 PC300LC-8 PC350-8 PC350LC-8 Excavator Shop Manual PDF
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Komatsu PC300-8 PC300LC-8 PC350-8 PC350LC-8 Excavator Shop Manual PDF

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Komatsu PC300-8 PC300LC-8 PC350-8 PC350LC-8 Hydraulic Excavator Shop Manual SEN01983-21 – PDF DOWNLOAD 

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 Hydraulic Excavator Shop Manual SEN01983-21 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC300-8 PC300LC-8 PC350-8 PC350LC-8 Hydraulic Excavator Shop Manual SEN01983-21 – PDF DOWNLOAD 

Language : English
Pages : 1080
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC300-8 PC300LC-8 PC350-8 PC350LC-8 Hydraulic Excavator Shop Manual SEN01983-21 – PDF DOWNLOAD 

SERIAL NUMBERS
PC300- 60001 and up
PC300LC- 60001 and up
PC350- 60001 and up
PC350LC- 60001 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.

TABLE OF CONTENTS:

Komatsu PC300-8 PC300LC-8 PC350-8 PC350LC-8 Hydraulic Excavator Shop Manual SEN01983-21 – PDF DOWNLOAD 

SERIAL NUMBERS
PC300- 60001 and up
PC300LC- 60001 and up
PC350- 60001 and up
PC350LC- 60001 and up

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
Dimensions 58
Working ranges 59
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
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
Anti-drop valve for boom 222
Anti-drop valve for arm 228
Return oil filter 235
Center swivel joint 236
Travel motor 237
Swing motor 249
Hydraulic cylinder 258
Work equipment 261
Work equipment 262
Dimensions of components 264
Cab and its attachments 269
Air conditioner piping 270
Electrical system 273
Engine control 274
Electronic control system 283
Monitor system 308
Sensor 335
KOMTRAX system 338
20 Standard value table 341
Standard service value table 341
Standard value table for engine related parts 342
Standard value table for chassis related parts 343
30 Testing and adjusting 355
Testing and adjusting, Part 1 355
Tools for testing, adjusting and troubleshooting 357
Sketches of special tools 361
Testing engine speed 362
Testing air boost pressure 363
Testing exhaust gas color 364
Adjusting valve clearance 366
Testing compression pressure 368
Testing blow-by pressure 372
Testing engine oil pressure 373
Testing fuel pressure 374
Handling during cylinder cut-out operation 379
Handling during no injection cranking operation 379
Testing fuel return rate and leakage 380
Bleeding air from fuel circuit 382
Checking fuel circuit for leakage 383
Testing and adjusting air compressor belt tension 384
Replacing fan belt 385
Replacing alternator belt 386
Testing clearance in swing circle bearings 387
Testing and adjusting track shoe tension 388
Testing and adjusting oil pressure in work equipment, swing and travel circuit 389
Testing and adjusting control circuit oil pressure 393
Testing and adjusting pump PC control circuit oil pressure 394
Testing and adjusting pump LS control circuit oil pressure 397
Testing solenoid valve output pressure 402
Testing PPC valve output pressure 406
Adjusting play of work equipment and swing PPC valves 407
Inspecting locations of hydraulic drift of work equipment 408
Releasing remaining pressure from hydraulic system 410
Testing oil leakage amount 414
Bleeding air from various parts 416
Diode inspection procedures 418
Installation and adjustment of mirrors 419
Testing and adjusting, Part 2 423
Special functions of machine monitor 424
Testing and adjusting, Part 3 481
Handling voltage circuit of engine controller 482
Preparation work for troubleshooting of electrical system 483
Procedure for testing diodes 487
Pm clinic service 488
40 Troubleshooting 495
Failure code table and fuse locations 495
Failure codes table 496
Fuse locations 499
General Information on troubleshooting 505
Points to remember when troubleshooting 506
Sequence of events in troubleshooting 507
Checks before troubleshooting 508
Classification and troubleshooting steps 509
Information in troubleshooting table 510
Possible problems and troubleshooting No 512
Connection table for connector pin numbers 515
T- branch box and T- branch adapter table 551
Troubleshooting by failure code (Display of code), Part 1 555
Failure code [989L00] Engine Controller Lock Caution 1 557
Failure code [989M00] Engine Controller Lock Caution 2 557
Failure code [989N00] Engine Controller Lock Caution 3 558
Failure code [AA10NX] Air cleaner Clogging 560
Failure code [AB00KE] Charge Voltage Low 562
Failure code [B@BAZG] Eng Oil Press Low 564
Failure code [B@BAZK] Eng Oil Level Low 566
Failure code [B@BCNS] Eng Water Overheat 568
Failure code [B@BCZK] Eng Water Level Low 570
Failure code [B@HANS] Hydr Oil Overheat 572
Failure code [CA111] EMC Critical Internal Failure 573
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 573
Failure code [CA122] Chg Air Press Sensor High Error 574
Failure code [CA123] Chg Air Press Sensor Low Error 576
Failure code [CA131] Throttle Sensor High Error 578
Failure code [CA132] Throttle Sensor Low Error 580
Failure code [CA144] Coolant Temp Sens High Error 582
Failure code [CA145] Coolant Temp Sens Low Error 584
Failure code [CA153] Chg Air Temp Sensor High Error 586
Failure code [CA154] Chg Air Temp Sensor Low Error 588
Failure code [CA155] Chg Air Temp High Speed Derate 590
Failure code [CA187] Sens Supply 2 Volt Low Error 592
Failure code [CA221] Ambient Press Sens High Error 594
Failure code [CA222] Ambient Press Sens Low Error 596
Failure code [CA227] Sens Supply 2 Volt High Error 598
Failure code [CA234] Eng Overspeed 599
Failure code [CA238] Ne Speed Sens Supply Volt Error 600
Failure code [CA271] IMV/PCV1 Short Error 601
Failure code [CA272] IMV/PCV1 Open Error 602
Failure code [CA281] Pump Press Balance Error 604
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error 605
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error 607
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error 609
Failure code [CA325] Inj #6 (L/B#6) Open/Short Error 611
Failure code [CA331] Inj #2 (L/B#2) Open/Short Error 613
Failure code [CA332] Inj #4 (L/B#4) Open/Short Error 615
Troubleshooting by failure code (Display of code), Part 2 619
Failure code [CA342] Calibration Code Incompatibility 621
Failure code [CA351] Injectors Drive Circuit Error 622
Failure code [CA352] Sens Supply 1 Volt Low Error 624
Failure code [CA386] Sens Supply 1 Volt High Error 626
Failure code [CA428] Water in Fuel Sensor High Error 628
Failure code [CA429] Water in Fuel Sensor Low Error 630
Failure code [CA435] Eng Oil Press Sw Error 632
Failure code [CA441] Battery Voltage Low Error 634
Failure code [CA442] Battery Voltage High Error 636
Failure code [CA449] Rail Press Very High Error 638
Failure code [CA451] Rail Press Sensor High Error 642
Failure code [CA452] Rail Press Sensor Low Error 644
Failure code [CA488] Chg Air Temp High Torque Derate 646
Failure code [CA553] Rail Press High Error 646
Failure code [CA559] Rail Press Low Error 648
Failure code [CA689] Eng Ne Speed Sensor Error 650
Failure code [CA731] Eng Bkup Speed Sens Phase Error 652
Failure code [CA757] All Persistent Data Lost Error 654
Failure code [CA778] Eng Bkup Speed Sensor Error 656
Failure code [CA1633] KOMNET Datalink Timeout Error 658
Failure code [CA2185] Throt Sens Sup Volt High Error 660
Failure code [CA2186] Throt Sens Sup Volt Low Error 661
Failure code [CA2249] Rail Press Very Low Error 662
Failure code [CA2265] Fuel Feed Pump Open Error 664
Failure code [CA2266] Fuel Feed Pump Short Error 666
Failure code [CA2311] IMV Solenoid Error 668
Failure code [CA2555] Grid Htr Relay Volt Low Error 670
Failure code [CA2556] Grid Htr Relay Volt High Error 672
Failure code [D110KB] Battery Relay Drive S/C 674
Failure code [D19JKZ] Personal Code Relay Abnormality 676
Failure code [D862KA] GPS Antenna Discon 678
Failure code [DA22KK] Pump Solenoid Power Low Error 679
Failure code [DA25KP] 5V sensor 1 power abnormality 681
Failure code [DA29KQ] Model Selection Abnormality 684
Failure code [DA2RMC] Pump Comm Abnormality 686
Failure code [DAF8KB] Short circuit in camera power supply 688
Failure code [DAFGMC] GPS Module Error 690
Troubleshooting by failure code (Display of code), Part 3 693
Failure code [DAFRMC] CAN discon (Monitor detected) 696
Failure code [DGH2KB] Hydr Oil Sensor Short 698
Failure code [DHPAMA] F Pump Press Sensor Abnormality 700
Failure code [DHPBMA] R Pump Press Sensor Abnormality 702
Failure code [DHS3MA] Arm Curl PPC Sensor Abnormality 704
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 706
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) 708
Failure code [DW43KA] Travel Speed Sol Open Circuit 710
Failure code [DW43KB] Travel Speed Sol Short Circuit 712
Failure code [DW45KA] Swing Brake Sol Open Circuit 714
Failure code [DW45KB] Swing Brake Sol Short Circuit 718
Failure code [DW91KA] Travel Junction Sol Open Circuit 720
Failure code [DW91KB] Travel Junction Sol Short Circuit 722
Failure code [DWA2KA] Attachment Sol Open Circuit 724
Failure code [DWA2KB] Attachment Sol Short Circuit 725
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 726
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 728
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 730
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 732
Failure code [DXA0KA] PC-EPC Sol Open Circuit 734
Failure code [DXA0KB] PC-EPC Sol Short Circuit 736
Failure code [DXE0KA] LS-EPC Sol Open Circuit 738
Failure code [DXE0KB] LS-EPC Sol Short Circuit 740
Failure code [DXE4KA] Service Current EPC Open Circuit 742
Failure code [DXE4KB] Service Current EPC Short Circuit 743
Failure code [DY20KA] Wiper Working Abnormality 744
Failure code [DY20MA] Wiper Parking Abnormality 746
Failure code [DY2CKA] Washer Drive Open Circuit 748
Failure code [DY2CKB] Washer Drive Short Circuit 750
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 752
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 754
Troubleshooting of electrical system (E-mode) 757
Before carrying out troubleshooting of electrical system 760
Information contained in troubleshooting table 762
E-1 Engine does not start 763
E-2 Auto-decelerator does not operate 766
E-3 Automatic warming-up system does not operate 768
E-4 Preheater does not operate 770
E-5 All work equipment, swing, and travel mechanism do not move 772
E-6 Power maximizing function does not operate 774
E-7 Machine monitor does not display at all 776
E-8 Machine monitor does not display some items 778
E-9 Contents of display by machine monitor are different from applicable machine 778
E-10 Fuel level monitor was lighted in red while engine running 779
E-11 Engine coolant temperature gauge does not indicate normally 780
E-12 Hydraulic oil temperature gauge does not indicate normally 782
E-13 Fuel level gauge does not indicate normally 783
E-14 Swing lock monitor does not indicate normally 784
E-15 When monitor switch is operated, monitor displays nothing 786
E-16 Windshield wiper and window washer do not operate 788
E-17 Machine push-up function does not operate normally 792
E-18 Monitoring function fails to display “boom raise” normally 794
E-19 Monitoring function fails to display “boom lower” normally 796
E-20 Monitoring function fails to display “arm IN” normally 798
E-21 Monitoring function fails to display “arm OUT” normally 800
E-22 Monitoring function fails to display “bucket CURL” normally 802
E-23 Monitoring function fails to display “bucket DUMP” normally 804
E-24 Monitoring function fails to display “swing” normally 806
E-25 Monitoring function fails to display “travel” normally 808
E-26 Monitoring function fails to display “travel differential pressure” normally 810
E-27 Monitoring function fails to display “service” normally 812
E-28 KOMTRAX system does not operate normally 814
E-29 Air conditioner does not operate 816
E-30 Travel alarm does not sound or does not stop sounding 818
E-31 Horn does not sound 820
Troubleshooting of hydraulic and mechanical system (H-mode) 823
System chart for hydraulic and mechanical system 826
Information contained in troubleshooting table 828
H-1 All work equipment lack power, or travel and swing speeds are slow 830
H-2 Engine speed sharply drops or engine stalls 832
H-3 No work equipment, swing or travel move 833
H-4 Abnormal noise is heard from around hydraulic pump 833
H-5 Auto-decelerator does not work 834
H-6 Fine control mode does not function or responds slow 834
H-7 Boom moves slowly or lacks power 835
H-8 Arm moves slowly or lacks power 836
H-9 Bucket moves slowly or lacks power 837
H-10 Work equipment does not move in its single operation 837
H-11 Work equipment has a bit too fast hydraulic drift 838
H-12 Work equipment has big time lag 840
H-13 Other work equipment moves when relieving single circuit 840
H-14 Power max switch does not operate 841
H-15 In compound operation, work equipment with larger load moves slowly 841
H-16 In swing + boom RAISE operation, boom moves slowly 842
H-17 In swing + travel operation, travel speed drops sharply 842
H-18 Machine swerves in travel 843
H-19 Machine travels slowly 844
H-20 Machine cannot be easily steered or lacks power 845
H-21 Travel speed does not shift, or it is too slow or fast 846
H-22 Track shoe does not turn (on one side only) 847
H-23 Machine does not swing 848
H-24 Swing acceleration is poor, or swing speed is slow 850
H-25 Excessive overrun when stopping swing 852
H-26 There is big shock when stopping swing 853
H-27 Large sound is made when upper structure stops swinging 853
H-28 Swing hydraulic drift is too big 854
Troubleshooting of engine (S-mode) 857
Method of using troubleshooting chart 859
S-1 Starting performance is poor 862
S-2 Engine does not start 863
S-3 Engine does not pick up smoothly 866
S-4 Engine stops during operations 867
S-5 Engine does not rotate smoothly 868
S-6 Engine lacks output (or lacks power) 869
S-7 Exhaust smoke is black (incomplete combustion) 870
S-8 Oil consumption is excessive (or exhaust smoke is blue) 871
S-9 Oil becomes contaminated quickly 872
S-10 Fuel consumption is excessive 873
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 874
S-12 Oil pressure drops 875
S-13 Oil level rises (Entry of coolant or fuel) 876
S-14 Coolant temperature becomes too high (overheating) 877
S-15 Abnormal noise is made 878
S-16 Vibration is excessive 879
50 Disassembly and assembly 881
General information on disassembly andassembly 881
How to read this manual 882
Coating materials list 884
Special tool list 887
Sketches of special tools 890
Engine and cooling system 895
Removal and installation of fuel supply pump assembly 896
Removal and installation of engine front seal 899
Removal and installation of engine rear seal 902
Removal and installation of cylinder head assembly 907
Removal and installation of radiator assembly 920
Removal and installation of hydraulic oil cooler assembly 922
Removal and installation of aftercooler assembly 924
Removal and installation of engine and hydraulic pump assembly 925
Power train 931
Removal and installation of final drive assembly 932
Disassembly and assembly of final drive assembly 933
Removal and installation of swing motor and swing machinery assembly 941
Disassembly and assembly of swing motor and swing machinery assembly 942
Removal and installation of swing circle assembly 949
Undercarriage and frame 951
Disassembly and assembly of carrier roller 952
Disassembly and assembly of track roller assembly 953
Disassembly and assembly of idler assembly 954
Disassembly and assembly of recoil spring 957
Removal and installation of sprocket 959
Expansion and installation of track shoe assembly 960
Removal and installation of revolving frame assembly 962
Removal and installation of counterweight assembly 964
Hydraulic system 969
Removal and installation of center swivel joint assembly 970
Disassembly and assembly of center swivel joint assembly 972
Removal and installation of hydraulic tank assembly 973
Removal and installation of control valve assembly 975
Disassembly and assembly of control valve assembly 978
Removal and installation of hydraulic pump assembly 979
Removal and installation of oil seal in hydraulic pump input shaft 981
Disassembly and assembly of work equipment PPC valve assembly 982
Disassembly and assembly of travel PPC valve assembly 984
Disassembly and assembly of hydraulic cylinder assembly 987
Work equipment 993
Removal and installation of work equipment assembly 994
Removal and installation of anti- drop valve assembly for boom 997
Removal and installation of anti- drop valve assembly for arm 1000
Disassembly and assembly of anti-drop valve assembly 1002
Cab and its attachments 1005
Removal and installation of operator’s cab assembly 1006
Removal and installation of operator cab glass (stuck glass) 1009
Removal and installation of front window assembly 1019
Removal and installation of floor frame assembly 1026
Removal and installation of work equipment control lever assembly 1030
Electrical system 1045
Removal and installation of air conditioner unit assembly 1046
Removal and installation of KOMTRAX communication modem assembly 1049
Removal and installation of monitor assembly 1050
Removal and installation of pump controller assembly 1052
Removal and installation of engine controller 1054
90 Diagrams and drawings 1057
Hydraulic diagrams and drawings 1057
Hydraulic circuit diagram 1059
Electrical diagrams and drawings 1065
Electrical circuit diagram 1067
Connector list and sterogram 1077

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