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KOMATSU PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 PC360-8M2 PC360LC-8M2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06931-03 – PDF DOWNLOAD
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KOMATSU PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 PC360-8M2 PC360LC-8M2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06931-03 – PDF DOWNLOAD
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KOMATSU PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 PC360-8M2 PC360LC-8M2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06931-03 – PDF DOWNLOAD
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KOMATSU PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 PC360-8M2 PC360LC-8M2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06931-03 – PDF DOWNLOAD
Language : English
Pages : 2066
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 PC360-8M2 PC360LC-8M2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06931-03 – PDF DOWNLOAD
Cover................................................................................................................................... 1 00 Index and Foreword.............................................................................................................. 3 Index.......................................................................................................................... 4 Abbreviation List.............................................................................................................. 15 Foreword, Safety, Basic Information............................................................................................ 18 How to Read the Shop Manual................................................................................................ 18 Safety Notice for Operation................................................................................................ 20 Precautions to Prevent Fire................................................................................................ 28 Procedures If Fire Occurs.................................................................................................. 29 Precautions When You Dispose of Waste Materials............................................................................ 30 Precautions When You Handle Hydraulic Equipment............................................................................ 31 Precautions When You Disconnect and Connect Pipings........................................................................ 34 Precautions When You Handle Electrical Equipment........................................................................... 41 Precautions When You Handle Fuel System Equipment.......................................................................... 43 Precautions When You Handle Intake System Equipment........................................................................ 44 Practical Use of KOMTRAX................................................................................................... 45 Disconnect and Connect Push-Pull Type Coupler.............................................................................. 46 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................ 46 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................ 47 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................ 48 Precautions for Disconnection and Connection of Connectors................................................................. 50 How to Disconnect and Connect Deutsch Connector............................................................................ 54 How to Disconnect and Connect Slide Lock Type Connector.................................................................... 55 How to Disconnect and Connect Connector with Lock to Pull.................................................................. 57 How to Disconnect and Connect Connector with Lock to Push.................................................................. 58 How to Disconnect and Connect Connector with Housing to Rotate............................................................. 60 How to Read the Codes for Electric Cable................................................................................... 61 Explanation of Terms for Maintenance Standard.............................................................................. 65 Standard Tightening Torque Table........................................................................................... 68 Conversion Table........................................................................................................... 75 01 Specifications.................................................................................................................. 81 Table of Contents.............................................................................................................. 82 Specifications................................................................................................................. 83 Specification Drawing...................................................................................................... 83 Specification Drawing: PC300-8M2....................................................................................... 83 Specification Drawing: PC300LC-8M2..................................................................................... 84 Specification Drawing: PC350-8M2....................................................................................... 84 Specification Drawing: PC350LC-8M2..................................................................................... 85 Specification Drawing: PC360-8M2....................................................................................... 86 Specification Drawing: PC360LC-8M2..................................................................................... 86 Working Range Drawings..................................................................................................... 88 Working Range Drawings: PC300-8M2...................................................................................... 88 Working Range Drawings: PC300LC-8M2.................................................................................... 89 Working Range Drawings: PC350-8M2...................................................................................... 90 Working Range Drawings: PC350LC-8M2.................................................................................... 91 Working Range Drawings: PC360-8M2...................................................................................... 92 Working Range Drawings: PC360LC-8M2.................................................................................... 93 Specifications............................................................................................................. 94 Specifications: PC300-8M2.............................................................................................. 94 Specifications: PC300LC-8M2............................................................................................ 96 Specifications: PC350-8M2.............................................................................................. 99 Specifications: PC350LC-8M2............................................................................................ 102 Specifications: PC360-8M2.............................................................................................. 104 Specifications: PC360LC-8M2............................................................................................ 107 Weight Table............................................................................................................... 111 Weight Table: PC300-8M2................................................................................................ 111 Weight Table: PC300LC-8M2.............................................................................................. 112 Weight Table: PC350-8M2................................................................................................ 113 Weight Table: PC350LC-8M2.............................................................................................. 114 Weight Table: PC360-8M2................................................................................................ 116 Weight Table: PC360LC-8M2.............................................................................................. 117 Fuel, Coolant, Lubricant................................................................................................... 119 How to Use Fuel, Coolant and Lubricants by Ambient Temperature......................................................... 119 10 Structure and Function.......................................................................................................... 121 Table of Contents.............................................................................................................. 122 Boot-up System................................................................................................................. 125 Layout Drawing of Boot-up System........................................................................................... 125 System Operating Lamp System............................................................................................... 126 System Diagram of System Operating Lamp System......................................................................... 126 Function of Operation Lamp System...................................................................................... 126 Operation of System Operating Lamp..................................................................................... 126 Battery Disconnect Switch.................................................................................................. 127 Function of Battery Disconnect Switch.................................................................................. 127 Operation of Battery Disconnect Switch................................................................................. 127 Engine System.................................................................................................................. 128 Layout Drawing of Engine System............................................................................................ 128 Engine Control System...................................................................................................... 130 System Diagram of Engine Control....................................................................................... 130 Operation of Engine Control System..................................................................................... 130 Auto-Deceleration System................................................................................................... 132 System Diagram of Auto-Deceleration System............................................................................. 132 Function of Auto-Deceleration System................................................................................... 132 Operation of Auto-Deceleration System.................................................................................. 133 Engine Automatic Warm-up System............................................................................................ 134 System Diagram of Engine Automatic Warm-up System...................................................................... 134 Function of Engine Automatic Warm-up System............................................................................ 134 Operation of Engine Automatic Warm-up System........................................................................... 134 Overheat Prevention System................................................................................................. 135 Overheat Prevention System Diagram..................................................................................... 135 Function of Overheat Prevention System................................................................................. 135 Turbocharger Protection System............................................................................................. 137 Function of Turbocharger Protection System............................................................................. 137 Cooling System................................................................................................................. 138 Layout Drawing of Cooling System........................................................................................... 138 Specifications of Cooling System....................................................................................... 138 Control System................................................................................................................. 139 Layout Drawing of Control System........................................................................................... 139 Machine Monitor System..................................................................................................... 141 System Diagram of Machine Monitor System............................................................................... 141 Function of Machine Monitor System..................................................................................... 141 KOMTRAX System............................................................................................................. 143 System Diagram of KOMTRAX System....................................................................................... 143 Function of KOMTRAX System............................................................................................. 143 Component Parts of Control System.......................................................................................... 144 Machine Monitor........................................................................................................ 144 Gateway Function Controller............................................................................................ 154 Communication Terminal................................................................................................. 157 Pump Controller........................................................................................................ 159 Resistor for PC-EPC Valve.............................................................................................. 163 CAN Terminating Resistor............................................................................................... 163 Engine Controller...................................................................................................... 164 Fuel Control Dial...................................................................................................... 168 Hydraulic System............................................................................................................... 169 Layout Drawing of Hydraulic System......................................................................................... 169 CLSS....................................................................................................................... 172 Structure of CLSS...................................................................................................... 172 Operation of Unload Valve and LS Pressure.............................................................................. 174 Pump Swash Plate Angle (Oil Flow) Control.............................................................................. 175 Pressure Compensation Control.......................................................................................... 188 Engine and Pump Combined Control System.................................................................................... 189 Engine and Pump Combined Control System Diagram........................................................................ 189 Function of Engine and Pump Combined Control System.................................................................... 190 Pump and Valve Control System.............................................................................................. 195 Pump and Valve Control System Diagram.................................................................................. 195 Function of Pump and Valve Control System.............................................................................. 195 Component Parts of Hydraulic System........................................................................................ 197 Hydraulic Tank......................................................................................................... 197 Main Pump.............................................................................................................. 200 Control Valve.......................................................................................................... 220 Work Equipment System.......................................................................................................... 279 Layout Drawing of Work Equipment System.................................................................................... 279 One-Touch Power Maximizing System.......................................................................................... 283 System Diagram of One-Touch Power Maximizing System.................................................................... 283 Function of One-Touch Power Maximizing System.......................................................................... 283 Machine Push-up System..................................................................................................... 285 Machine Push-up System Diagram......................................................................................... 285 Function of Machine Push-up System..................................................................................... 285 PPC Lock System............................................................................................................ 287 System Diagram of PPC Lock............................................................................................. 287 Function of PPC Lock System............................................................................................ 288 Attachment Oil Flow Adjuster System........................................................................................ 289 Attachment Oil Flow Adjuster System Diagram............................................................................ 289 Function of Attachment Oil Flow Adjuster System........................................................................ 289 Component Parts of Work Equipment System................................................................................... 290 Work Equipment and Swing PPC Valve..................................................................................... 290 1st-Line Attachment PPC Valve (with EPC Valve)......................................................................... 295 2nd-Line Attachment PPC Valve.......................................................................................... 298 Solenoid Valve......................................................................................................... 300 Attachment Circuit Selector Valve (For High Pressure).................................................................. 302 Attachment Circuit Selector Valve (For Low Pressure)................................................................... 303 Pilot Circuit Accumulator.............................................................................................. 306 Attachment Circuit Accumulator......................................................................................... 306 Swing System................................................................................................................... 309 Layout Drawing of Swing System............................................................................................. 309 Swing Control System Diagram............................................................................................... 311 Function of Swing Control System....................................................................................... 311 Component Parts of Swing System............................................................................................ 313 Swing Motor............................................................................................................ 313 Swing Machinery........................................................................................................ 321 Swing Circle........................................................................................................... 323 Travel System.................................................................................................................. 325 Layout Drawing of Travel System............................................................................................ 325 System Diagram of Travel Control System.................................................................................... 327 Function of Travel Control System...................................................................................... 327 Component Parts of Travel System........................................................................................... 329 Travel Motor........................................................................................................... 329 Final Drive............................................................................................................ 341 Travel PPC Valve....................................................................................................... 342 Center Swivel Joint.................................................................................................... 347 Undercarriage and Frame........................................................................................................ 349 Layout Drawing of Undercarriage............................................................................................ 349 Specifications of Undercarriage........................................................................................ 349 Work Equipment................................................................................................................. 351 Structure of Work Equipment................................................................................................ 351 Work Equipment Clearance Adjustment Shim................................................................................... 352 Function of Work Equipment Clearance Adjustment Shim................................................................... 352 Bucket Clearance Adjustment Shim........................................................................................... 353 Function of Bucket Clearance Adjustment Shim........................................................................... 353 CAB Related Parts.............................................................................................................. 354 ROPS CAB................................................................................................................... 354 Structure of ROPS CAB.................................................................................................. 354 Function of ROPS CAB................................................................................................... 354 CAB Mount.................................................................................................................. 355 Structure of CAB Mount................................................................................................. 355 Function of CAB Mount.................................................................................................. 356 CAB Tipping Stopper........................................................................................................ 357 Structure of CAB Tipping Stopper....................................................................................... 357 Function of CAB Tipping Stopper........................................................................................ 357 20 Standard Value Table............................................................................................................ 359 Table of Contents.............................................................................................................. 360 Standard Value Table for Engine................................................................................................ 361 Standard Value Table for Engine: PC300,300LC-8M2/PC350,350LC-8M2/PC360,360LC-8M2........................................... 361 Standard Value Table for Machine............................................................................................... 364 Standard Value Table for Machine: PC300,300LC-8M2/PC350,350LC-8M2/PC360,360LC-8M2.......................................... 364 Machine Posture and Procedures to Measure Performance...................................................................... 376 30 Testing and Adjusting........................................................................................................... 379 Table of Contents.............................................................................................................. 380 Precautions Before Work........................................................................................................ 383 Related Information on Testing and Adjusting................................................................................... 384 Tools for Testing and Adjusting............................................................................................ 384 Sketch of Tools for Testing and Adjusting.................................................................................. 389 Engine and Cooling System...................................................................................................... 390 Examine Engine Speed....................................................................................................... 390 How to Examine Engine High Idle Speed.................................................................................. 390 How to Examine Engine Low Idle Speed................................................................................... 390 How to Examine Engine Speed at 2 Pump Relief........................................................................... 390 Test Engine Speed at 2 Pumps Relief and One-touch Power Maximizing..................................................... 391 How to Examine Engine Speed with Auto-Deceleration..................................................................... 391 Examine Boost Pressure..................................................................................................... 393 How to Examine Boost Pressure on Machine Monitor....................................................................... 393 How to Examine Boost Pressure by Testing Tool.......................................................................... 394 Examine Exhaust Gas Color.................................................................................................. 396 How to Examine Exhaust Gas Color with the Handy Smoke Checker.......................................................... 396 How to Examine Exhaust Gas Color with Smoke Meter...................................................................... 397 Examine and Adjust Valve Clearance......................................................................................... 398 How to Examine Valve Clearance......................................................................................... 398 How to Adjust Valve Clearance.......................................................................................... 400 Examine Compression Pressure............................................................................................... 401 How to Examine Compression Pressure.................................................................................... 401 Examine Blowby Pressure.................................................................................................... 406 How to Examine Blowby Pressure on Machine Monitor (Machine with Blowby Pressure Sensor (OPT)).......................... 406 How to Test Blowby Pressure by Testing Tool (Machine Without Blowby Pressure Sensor)................................... 407 Examine Engine Oil Pressure................................................................................................ 409 How to Examine Engine Oil Pressure..................................................................................... 409 Examine Fuel Pressure...................................................................................................... 411 How to Examine Fuel Pressure........................................................................................... 412 Test Fuel Return Rate and Leakage.......................................................................................... 417 How to Examine Fuel Return Rate and Leakage............................................................................ 418 Bleed Air from Fuel System................................................................................................. 421 How to Bleed Air from Fuel System...................................................................................... 421 Examine Fuel Circuit for Leakage........................................................................................... 422 How to Examine Fuel System for Leakage................................................................................. 422 Handle Cylinder Cut-out Mode Operation..................................................................................... 424 Handle No-Injection Cranking Operation..................................................................................... 425 Examine and Adjust Air Conditioner Compressor Belt Tension................................................................. 426 How to Examine Air Conditioner Compressor Belt Tension................................................................. 426 How to Adjust Air Conditioner Compressor Belt Tension.................................................................. 426 Power Train.................................................................................................................... 427 Examine Swing Circle Bearing Clearance..................................................................................... 427 How to Examine Swing Circle Bearing Clearance.......................................................................... 427 Undercarriage and Frame........................................................................................................ 428 Examine and Adjust Track Tension........................................................................................... 428 How to Examine Track Tension........................................................................................... 428 How to Adjust Track Tension............................................................................................ 428 Hydraulic System............................................................................................................... 430 Release Remained Pressure in Hydraulic Circuit............................................................................. 430 How to Release Remained Pressure from Hydraulic Tank................................................................... 430 How to Release Remained Pressure in Hydraulic Cylinder Circuit......................................................... 430 How to Release Remained Pressure from Swing Motor Circuit.............................................................. 434 How to Release Remained Pressure from Travel Motor Circuit............................................................. 434 Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits.............................................. 436 How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits.............................................. 436 How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits............................................... 443 Examine Oil Pressure of Control Circuit.................................................................................... 446 How to Examine Oil Pressure in Control Circuit......................................................................... 446 Examine and adjust oil pressure in pump PC control circuit................................................................. 448 How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure).................................................. 448 How to Examine PC-EPC Valve Outlet Pressure............................................................................ 450 How to Adjust Oil Pressure in Pump PC Control Circuit.................................................................. 451 Examine and Adjust Oil Pressure in Pump LS Control Circuit................................................................. 452 How to Examine LS Differential Pressure by Testing Tool................................................................ 452 How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure).................................................. 454 How to Examine LS-EPC Valve Outlet Pressure............................................................................ 456 How to Adjust LS Valve................................................................................................. 457 Examine Outlet Pressure of Solenoid Valve.................................................................................. 458 How to Examine Outlet Pressure of Solenoid Valve....................................................................... 458 Operating Condition of Solenoid Valve.................................................................................. 460 Examine PPC Valve Outlet Pressure.......................................................................................... 462 How to Examine PPC Valve Outlet Pressure on Machine Monitor............................................................ 462 How to Examine PPC Valve Outlet Pressure by Testing Tool............................................................... 463 Adjust Play of Work Equipment and Swing PPC Valve.......................................................................... 465 How to Adjust play of work equipment and swing PPC valve............................................................... 465 Examine parts which cause hydraulic drift of work equipment................................................................ 466 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder.................................. 466 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder................................................... 466 How to Examine Parts Which Cause Hydraulic Drift of Boom Hydraulic Drift Prevention Valve.............................. 467 How to Examine Parts Which Cause Hydraulic Drift of PPC Valve.......................................................... 467 Examine Oil Leakage........................................................................................................ 468 How to Examine Oil Leakage from Travel Motor........................................................................... 468 How to Examine Oil Leakage from Swing Motor............................................................................ 469 How to Examine Oil Leakage from Boom Cylinder.......................................................................... 470 How to Examine Oil Leakage from Arm Cylinder........................................................................... 471 How to Examine Oil Leakage from Bucket Cylinder........................................................................ 471 Bleed Air from Hydraulic System............................................................................................ 473 How to Bleed Air from Main Pump........................................................................................ 474 How to Bleed Air from Cylinder......................................................................................... 475 How to Bleed Air from Swing Motor...................................................................................... 476 How to Bleed Air from Travel Motor..................................................................................... 476 CAB Related Parts.............................................................................................................. 478 Examine CAB Tipping Stopper................................................................................................ 478 How to Examine Cab Tipping Stopper..................................................................................... 478 How to Adjust Mirrors...................................................................................................... 479 Procedure to Adjust Machine Left Front Mirror (A)...................................................................... 479 Procedure to Adjust Regular Position of Machine Left Front Mirror (A).................................................. 480 Procedure to Adjust Machine Right Front Mirror (B)..................................................................... 481 Procedure to Adjust Regular Position of Machine Right Front Mirror (B)................................................. 482 Procedure to Adjust Machine Right Side Mirror (C)...................................................................... 483 Electrical System.............................................................................................................. 485 Set and Operate Machine Monitor............................................................................................ 485 Operator Mode.......................................................................................................... 489 Function to Show Technician Identification Status Screen............................................................... 489 Function to Show Operator Identification Input Screen.................................................................. 489 Examine Function by LCD (Liquid Crystal Display)....................................................................... 490 Examine Function of Service Meter...................................................................................... 490 How to Set Usage Limitation and Change Maintenance Password............................................................ 490 Service Mode........................................................................................................... 493 How to Operate Service Mode............................................................................................ 493 How to See Pre-defined Monitoring Information.......................................................................... 494 How to Examine Monitoring Information.................................................................................. 498 Abnormality Record Menu................................................................................................ 506 How to See Maintenance Record.......................................................................................... 509 Maintenance Mode Setting............................................................................................... 511 How to Set Phone Number Entry.......................................................................................... 515 Default Setting Menu................................................................................................... 516 Testing Menu........................................................................................................... 523 Adjustment Menu........................................................................................................ 525 No-Injection Cranking Operation........................................................................................ 535 KOMTRAX Settings Menu.................................................................................................. 538 How to Show Service Message............................................................................................ 540 How to Start Up KOMTRAX System (Machine with Gateway Function Controller).................................................. 542 How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)............................................... 548 Adjust Rearview Camera Angle............................................................................................... 550 How to Adjust Rearview Camera Angle.................................................................................... 550 Handle Voltage Circuit of Engine Controller................................................................................ 552 Handle Battery Disconnect Switch........................................................................................... 553 Examine Diodes............................................................................................................. 554 How to Examine Diodes by Digital Tester................................................................................ 554 How to Examine Diodes by Analog Tester................................................................................. 554 Pm Clinic...................................................................................................................... 555 Pm Clinic Service.......................................................................................................... 555 Pm Clinic Check Sheet: PC300,300LC-8M2/PC350,350LC-8M2/PC360,360LC-8M2................................................. 558 40 Troubleshooting................................................................................................................. 565 Table of Contents.............................................................................................................. 566 Precautions Before Work........................................................................................................ 572 Related Information to Troubleshooting......................................................................................... 573 General Troubleshooting Points............................................................................................. 573 Sequence of Events in Troubleshooting...................................................................................... 574 Checks Before Troubleshooting.............................................................................................. 576 Inspection Procedure Before Troubleshooting................................................................................ 578 Walk-Around Check...................................................................................................... 578 Examine Engine Related Parts........................................................................................... 579 Examine Work Equipment and Undercarriage............................................................................... 581 Examine Electric Equipment............................................................................................. 582 Preparation for Troubleshooting of Electrical System....................................................................... 587 Preparation for Troubleshooting of Machine Monitor..................................................................... 587 Preparation for Troubleshooting of Engine Controller................................................................... 587 Preparation for Troubleshooting of Pump Controller..................................................................... 588 Preparation for Troubleshooting of Gateway Function Controller......................................................... 588 How to Disconnect and Connect Connector with a Special Lock............................................................ 588 Disconnect and Connect Connector with Lock to Push......................................................................... 593 How to Disconnect and Connect Deutsch Connector........................................................................ 593 How to Disconnect and Connect BOSCH Connector.......................................................................... 593 How to Disconnect and Connect AMP Connector............................................................................ 594 How to Disconnect and Connect SUMITOMO Connector....................................................................... 595 How to Disconnect and Connect Connector with Lock to Pull.................................................................. 596 How to Disconnect and Connect DELPHI Connector and PACKARD Connector................................................... 596 How to Disconnect and Connect Slide Type Connector......................................................................... 597 How to Disconnect and Connect Framatome Connector...................................................................... 597 How to Disconnect and Connect TYCO Connector........................................................................... 598 How to Disconnect and Connect Connector with Housing to Rotate............................................................. 599 Procedure for Troubleshooting.............................................................................................. 600 Information Shown in Troubleshooting....................................................................................... 601 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness............................................ 604 Connectors List............................................................................................................ 607 Connector Layout........................................................................................................... 613 Connector Contact Connection Table......................................................................................... 619 T-Branch Box and T-Branch Adapter Table.................................................................................... 661 Fuse Location and Connection Table......................................................................................... 667 Failure Code Table......................................................................................................... 669 Troubleshooting by Failure Code (Display of Code).............................................................................. 677 Failure Code [602KNX]...................................................................................................... 677 Failure Code [879AKA]...................................................................................................... 680 Failure Code [879AKB]...................................................................................................... 682 Failure Code [879BKA]...................................................................................................... 684 Failure Code [879BKB]...................................................................................................... 687 Failure Code [879CKA]...................................................................................................... 690 Failure Code [879CKB]...................................................................................................... 692 Failure Code [879DKZ]...................................................................................................... 694 Failure Code [879EMC]...................................................................................................... 697 Failure Code [879FMC]...................................................................................................... 699 Failure Code [879GKX]...................................................................................................... 701 Failure Code [989L00]...................................................................................................... 704 Failure Code [989M00]...................................................................................................... 705 Failure Code [989N00]...................................................................................................... 706 Failure Code [AA10NX]...................................................................................................... 707 Failure Code [AB00KE]...................................................................................................... 710 Failure Code [B@BAZG]...................................................................................................... 712 Failure Code [B@BAZK]...................................................................................................... 713 Failure Code [B@BCNS]...................................................................................................... 715 Failure Code [B@BCQA]...................................................................................................... 716 Failure Code [B@BCZK]...................................................................................................... 718 Failure Code [B@HANS]...................................................................................................... 720 Failure Code [CA111]....................................................................................................... 721 Failure Code [CA115]....................................................................................................... 722 Failure Code [CA122]....................................................................................................... 723 Failure Code [CA123]....................................................................................................... 725 Failure Code [CA131]....................................................................................................... 727 Failure Code [CA132]....................................................................................................... 729 Failure Code [CA144]....................................................................................................... 731 Failure Code [CA145]....................................................................................................... 733 Failure Code [CA153]....................................................................................................... 735 Failure Code [CA154]....................................................................................................... 737 Failure Code [CA155]....................................................................................................... 739 Failure Code [CA187]....................................................................................................... 740 Failure Code [CA221]....................................................................................................... 742 Failure Code [CA222]....................................................................................................... 744 Failure Code [CA227]....................................................................................................... 746 Failure Code [CA234]....................................................................................................... 747 Failure Code [CA238]....................................................................................................... 748 Failure Code [CA271]....................................................................................................... 750 Failure Code [CA272]....................................................................................................... 752 Failure Code [CA281]....................................................................................................... 754 Failure Code [CA322]....................................................................................................... 755 Failure Code [CA323]....................................................................................................... 757 Failure Code [CA324]....................................................................................................... 759 Failure Code [CA325]....................................................................................................... 761 Failure Code [CA331]....................................................................................................... 763 Failure Code [CA332]....................................................................................................... 765 Failure Code [CA342]....................................................................................................... 767 Failure Code [CA351]....................................................................................................... 768 Failure Code [CA352]....................................................................................................... 769 Failure Code [CA386]....................................................................................................... 771 Failure Code [CA428]....................................................................................................... 772 Failure Code [CA429]....................................................................................................... 774 Failure Code [CA435]....................................................................................................... 776 Failure Code [CA441]....................................................................................................... 777 Failure Code [CA442]....................................................................................................... 779 Failure Code [CA449]....................................................................................................... 780 Failure Code [CA451]....................................................................................................... 781 Failure Code [CA452]....................................................................................................... 783 Failure Code [CA488]....................................................................................................... 785 Failure Code [CA553]....................................................................................................... 786 Failure Code [CA559]....................................................................................................... 787 Failure Code [CA689]....................................................................................................... 791 Failure Code [CA731]....................................................................................................... 796 Failure Code [CA757]....................................................................................................... 798 Failure Code [CA778]....................................................................................................... 799 Failure Code [CA2185]...................................................................................................... 804 Failure Code [CA2186]...................................................................................................... 806 Failure Code [CA2249]...................................................................................................... 808 Failure Code [CA2265]...................................................................................................... 809 Failure Code [CA2266]...................................................................................................... 811 Failure Code [CA2311]...................................................................................................... 813 Failure Code [CA2555]...................................................................................................... 814 Failure Code [CA2556]...................................................................................................... 817 Failure Code [D110KB]...................................................................................................... 819 Failure Code [D19JKZ]...................................................................................................... 822 Failure Code [D811MC]...................................................................................................... 827 Failure Code [D862KA]...................................................................................................... 828 Failure Code [D8ALKA]...................................................................................................... 830 Failure Code [D8ALKB]...................................................................................................... 834 Failure Code [D8AQKR]...................................................................................................... 837 Failure Code [D8ARKR]...................................................................................................... 846 Failure Code [D8G1KT]...................................................................................................... 852 Failure Code [D8G6KT]...................................................................................................... 853 Failure Code [DA20MC]...................................................................................................... 854 Failure Code [DA22KK]...................................................................................................... 855 Failure Code [DA25KP]...................................................................................................... 860 Failure Code [DA26KP]...................................................................................................... 865 Failure Code [DA29KQ]...................................................................................................... 869 Failure Code [DA2LKA]...................................................................................................... 874 Failure Code [DA2LKB]...................................................................................................... 878 Failure Code [DA2QKR]...................................................................................................... 881 Failure Code [DA2RKR]...................................................................................................... 892 Failure Code [DAF0MB]...................................................................................................... 901 Failure Code [DAF0MC]...................................................................................................... 902 Failure Code [DAF8KB]...................................................................................................... 903 Failure Code [DAF9KQ]...................................................................................................... 905 Failure Code [DAFGMC]...................................................................................................... 907 Failure Code [DAFLKA]...................................................................................................... 909 Failure Code [DAFLKB]...................................................................................................... 913 Failure Code [DAFQKR]...................................................................................................... 916 Failure Code [DAZ9KQ]...................................................................................................... 926 Failure Code [DAZQKR]...................................................................................................... 928 Failure Code [DB2QKR]...................................................................................................... 937 Failure Code [DDPAKA]...................................................................................................... 947 Failure Code [DGH2KA]...................................................................................................... 950 Failure Code [DGH2KB]...................................................................................................... 953 Failure Code [DHA4KA]...................................................................................................... 956 Failure Code [DHE5MA]...................................................................................................... 959 Failure Code [DHPAMA]...................................................................................................... 963 Failure Code [DHPBMA]...................................................................................................... 967 Failure Code [DHS3MA]...................................................................................................... 971 Failure Code [DHS4MA]...................................................................................................... 975 Failure Code [DHS8MA]...................................................................................................... 979 Failure Code [DHS9MA]...................................................................................................... 983 Failure Code [DHSAMA]...................................................................................................... 987 Failure Code [DHSBMA]...................................................................................................... 991 Failure Code [DHSCMA]...................................................................................................... 995 Failure Code [DHSDMA]...................................................................................................... 999 Failure Code [DHSFMA]......................................................................................................1003 Failure Code [DHSGMA]......................................................................................................1007 Failure Code [DHSHMA]......................................................................................................1011 Failure Code [DHSJMA]......................................................................................................1015 Failure Code [DKR2MA]......................................................................................................1019 Failure Code [DKR2NX]......................................................................................................1023 Failure Code [DR21KX]......................................................................................................1025 Failure Code [DR31KX]......................................................................................................1027 Failure Code [DV20KB]......................................................................................................1028 Failure Code [DW43KA]......................................................................................................1031 Failure Code [DW43KB]......................................................................................................1034 Failure Code [DW43KY]......................................................................................................1037 Failure Code [DW45KA]......................................................................................................1039 Failure Code [DW45KB]......................................................................................................1043 Failure Code [DW45KY]......................................................................................................1047 Failure Code [DW91KA]......................................................................................................1050 Failure Code [DW91KB]......................................................................................................1052 Failure Code [DW91KY]......................................................................................................1055 Failure Code [DWA2KA]......................................................................................................1057 Failure Code [DWA2KB]......................................................................................................1059 Failure Code [DWA2KY]......................................................................................................1062 Failure Code [DWJ0KA]......................................................................................................1064 Failure Code [DWJ0KB]......................................................................................................1066 Failure Code [DWJ0KY]......................................................................................................1068 Failure Code [DWK0KA]......................................................................................................1069 Failure Code [DWK0KB]......................................................................................................1071 Failure Code [DWK0KY]......................................................................................................1074 Failure Code [DWK2KA]......................................................................................................1076 Failure Code [DWK2KB]......................................................................................................1078 Failure Code [DWK2KY]......................................................................................................1081 Failure Code [DXA8KA]......................................................................................................1083 Failure Code [DXA8KB]......................................................................................................1086 Failure Code [DXE0KA]......................................................................................................1090 Failure Code [DXE0KB]......................................................................................................1093 Failure Code [DXE4KA]......................................................................................................1096 Failure Code [DXE4KB]......................................................................................................1099 Failure Code [DXE4KY]......................................................................................................1102 Failure Code [DY20KA]......................................................................................................1104 Failure Code [DY20MA]......................................................................................................1109 Failure Code [DY2CKB]......................................................................................................1113 Failure Code [DY2DKB]......................................................................................................1118 Failure Code [DY2EKB]......................................................................................................1121 Failure Code [F313KA]......................................................................................................1124 Failure Code [F313KB]......................................................................................................1126 Failure Code [F318KB]......................................................................................................1129 Failure Code [F318KY]......................................................................................................1132 Failure Code [F@BBZL]......................................................................................................1134 Troubleshooting of Electrical System (E-Mode)..................................................................................1137 Engine Does Not Start (Engine Does Not Crank)..............................................................................1137 Manual Preheating System Does Not Operate..................................................................................1147 Automatic Preheating System Does Not Operate...............................................................................1151 While Preheating is in Operation, Preheating Monitor Does Not Come On......................................................1155 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing...............................................1160 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow..........1163 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow....1165 Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation..........................................1167 Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation...........................................1169 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation...............................................1171 Charge Level Monitor Comes On in Red While Engine is in Operation..........................................................1173 Fuel Level Monitor Comes On in Red While Engine is in Operation............................................................1177 Water Separator Monitor Comes On in Red While Engine is in Operation.......................................................1178 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation...................................................1179 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation.............................................1180 Fuel Gauge Does Not Move from Minimum or Maximum...........................................................................1182 Display of Fuel Gauge is Different from Actual Fuel Level..................................................................1185 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum....................................................1187 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature..........................................1188 Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum......................................................1190 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature........................................1193 Machine Monitor Shows Incorrect Model......................................................................................1195 Some Areas of Machine Monitor Screen are Not Shown.........................................................................1196 Function Switch Does Not Operate...........................................................................................1197 Automatic Warm-up System Does Not Operate (in Cold Weather)................................................................1198 Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated............................1200 Auto-Decelerator is Not Operated or Canceled with Lever....................................................................1201 Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated..................................................1204 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed..........................................1205 Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated.................................................1206 Travel Speed Does Not Change Even When You Change Travel Speed.............................................................1207 Alarm Buzzer Does Not Stop.................................................................................................1209 Service Meter is Not Shown While Starting Switch is in OFF Position........................................................1210 Service Mode Cannot be Selected............................................................................................1211 All Work Equipment, Swing, Travel Do Not Operate...........................................................................1212 All Work Equipment, Swing, Travel Cannot be Locked.........................................................................1216 Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position.................................1218 While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated.........................................1222 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor is Not Shown.....................................1225 One-Touch Power Maximizing Function is Not Cancelled.......................................................................1229 Travel Alarm Does Not Operate During Travel................................................................................1231 Travel Alarm Does Not Stop When Machine Stops..............................................................................1234 Horn Does Not Sound........................................................................................................1236 Horn Does Not Stop.........................................................................................................1240 Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated....................................................1242 Windshield Wiper Does Not Operate When Wiper Switch is Operated............................................................1243 When Window Washer Switch is Operated, Window Washer Does Not Operate......................................................1246 Machine Push-up Function Cannot be Canceled................................................................................1249 Machine Push-up Function Does Not Operate..................................................................................1251 Boom Raise is Not Shown Normally with Monitoring Function..................................................................1253 Boom Lower is Not Shown Normally with Monitoring Function..................................................................1254 Arm OUT is Not Shown Correctly with Monitoring Function....................................................................1255 Arm IN is Not Shown Normally with Monitoring Function......................................................................1256 Bucket DUMP is Not Shown Correctly with Monitoring Function................................................................1257 Bucket CURL is Not Shown Correctly with Monitoring Function................................................................1258 Swing is Not Shown Normally with Monitoring Function.......................................................................1259 Travel is Not Shown Normally with Monitoring Function......................................................................1260 Service is Not Shown Correctly with Monitoring Function....................................................................1261 Attachment Hydraulic Circuit Cannot be Changed.............................................................................1264 KOMTRAX System Does Not Operate Correctly..................................................................................1266 Quick Coupler Does Not Work................................................................................................1268 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)..................................................................1273 Information Shown in Troubleshooting Table (H-Mode)........................................................................1273 All Work Equipment, Swing and Travel Do Not Work...........................................................................1274 All Work Equipment, Swing, and Travel Lack Speed or Power..................................................................1276 Fine Control Performance or Response is Unsatisfactory.....................................................................1287 Unusual Noise is Heard from Around Hydraulic Pump..........................................................................1292 Engine Speed Drops Largely or Engine Stops.................................................................................1294 Boom Speed or Power is Low.................................................................................................1303 Arm Speed or Power is Low..................................................................................................1315 Bucket Speed or Power is Low...............................................................................................1326 Work Equipment Does Not Move in Single Operation...........................................................................1336 Hydraulic Drift of Boom is Large...........................................................................................1340 Hydraulic Drift of Arm is Large............................................................................................1342 Hydraulic Drift of Bucket is Large.........................................................................................1346 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves...........................................1349 Time Lag of Work Equipment is Large........................................................................................1351 One-Touch Power Maximizing Function Does Not Operate.......................................................................1358 Attachment Circuit Cannot be Changed.......................................................................................1361 Oil Flow in Attachment Circuit Cannot be Changed...........................................................................1363 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower........................................1365 In Mixed Operation of Swing and Travel, Travel Speed Falls Largely.........................................................1367 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low........................................................1368 Machine Does Not Travel Straight...........................................................................................1369 Machine is Not Steered Well or Steering Power is Low.......................................................................1380 Travel Speed is Low........................................................................................................1396 One of Tracks Does Not Run.................................................................................................1407 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast..........................................................1417 Upper Structure Does Not Swing in Two Directions of Right and Left.........................................................1420 Machine Swings Only in One Direction.......................................................................................1425 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left...............................................1428 Swing Acceleration or Swing Speed is Low in Only One Direction.............................................................1435 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)...........................................1439 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction).......................................1441 Shock is Large When Upper Structure Stops Swing Operation..................................................................1445 Large Unusual Noise is Heard When Upper Structure Stops....................................................................1447 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied).....................................................1450 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)....................................................1452 Fan Speed is Abnormal (Too High or Low, or Does Not Move)..................................................................1456 Unusual Noise is Heard from Around Fan.....................................................................................1457 Troubleshooting of Engine (S-Mode).............................................................................................1458 Information Shown in Troubleshooting Table (S-Mode)........................................................................1458 Engine Does Not Crank When Starting Switch is Turned to Start Position.....................................................1459 Engine Cranks but No Exhaust Smoke Comes Out...............................................................................1460 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)....................................1461 Engine Startability is Unsatisfactory......................................................................................1463 Engine Does Not Pick Up Smoothly...........................................................................................1465 Engine Stops During Operation..............................................................................................1467 Engine Does Not Rotate Smoothly............................................................................................1469 Engine Lacks Output (or Lacks Power).......................................................................................1470 Exhaust Smoke is Black.....................................................................................................1472 Engine Oil Consumption is Excessive........................................................................................1474 Engine Oil Becomes Dirty Quickly...........................................................................................1475 Fuel Consumption is Excessive..............................................................................................1476 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)......................................................1477 Engine Oil Pressure Drops..................................................................................................1478 Fuel Mixes Into Engine Oil.................................................................................................1479 Water Mixes Into Engine Oil (Milky)........................................................................................1480 Coolant Temperature Increases Too High (Overheat)..........................................................................1481 Unusual Noise is Heard.....................................................................................................1482 Vibration is Excessive.....................................................................................................1483 Air Cannot be Bled from Fuel Circuit.......................................................................................1484 50 Disassembly and Assembly........................................................................................................1485 Table of Contents..............................................................................................................1486 Precautions Before Work........................................................................................................1489 Related Information on Disassembly and Assembly................................................................................1490 How to Read This Manual....................................................................................................1490 Coating Materials List.....................................................................................................1491 Special Tool List..........................................................................................................1496 Sketches of Special Tools..................................................................................................1502 Prepare........................................................................................................................1506 Drain and Add Coolant......................................................................................................1506 How to Drain Coolant...................................................................................................1506 How to Add Coolant.....................................................................................................1507 Drain and Add Hydraulic Oil................................................................................................1508 How to Drain Hydraulic Oil.............................................................................................1508 How to Add Hydraulic Oil...............................................................................................1508 Drain and Add Fuel.........................................................................................................1510 How to Drain Fuel......................................................................................................1510 How to Add Fuel........................................................................................................1510 Collect and Refill Refrigerant.............................................................................................1511 How to Collect Refrigerant.............................................................................................1511 How to Refill Refrigerant..............................................................................................1511 Engine and Cooling System......................................................................................................1513 Remove and Install Supply Pump Assembly....................................................................................1513 How to Remove Supply Pump Assembly.....................................................................................1513 How to Install Supply Pump Assembly....................................................................................1517 Remove and Install Cylinder Head Assembly..................................................................................1522 How to Remove Cylinder Head Assembly...................................................................................1522 How to Install Cylinder Head Assembly..................................................................................1529 Remove and Install Radiator Assembly.......................................................................................1544 How to Remove Radiator Assembly........................................................................................1544 How to Install Radiator Assembly.......................................................................................1546 Remove and Install Hydraulic Oil Cooler Assembly...........................................................................1549 How to Remove Hydraulic Oil Cooler Assembly............................................................................1549 How to Install Hydraulic Oil Cooler Assembly...........................................................................1551 Remove and Install Aftercooler Assembly....................................................................................1554 How to Remove Aftercooler Assembly.....................................................................................1554 How to Install Aftercooler Assembly....................................................................................1554 Remove and Install Engine and Main Pump Assembly...........................................................................1556 How to Remove Engine and Main Pump Assembly............................................................................1556 How to Install Engine and Main Pump Assembly...........................................................................1563 Remove and Install Engine Front Oil Seal...................................................................................1571 How to Remove Engine Front Oil Seal....................................................................................1571 How to Install Engine Front Oil Seal...................................................................................1572 Remove and Install Engine Rear Oil Seal....................................................................................1575 How to Remove Engine Rear Oil Seal.....................................................................................1575 How to Install Engine Rear Oil Seal....................................................................................1577 Power Train....................................................................................................................1581 Remove and Install Travel Motor and Final Drive Assembly...................................................................1581 How to Remove Travel Motor and Final Drive Assembly....................................................................1581 How to Install Travel Motor and Final Drive Assembly...................................................................1582 Disassemble and Assemble Final Drive Assembly..............................................................................1584 How to Disassemble Final Drive Assembly................................................................................1585 How to Assemble Final Drive Assembly...................................................................................1589 Remove and Install Swing Motor and Swing Machinery Assembly................................................................1597 How to Remove Swing Motor and Swing Machinery Assembly.................................................................1597 How to Install Swing Motor and Swing Machinery Assembly................................................................1598 Disassemble and Assemble Swing Machinery Assembly..........................................................................1600 How to Disassemble Swing Machinery Assembly............................................................................1600 How to Assemble Swing Machinery Assembly...............................................................................1603 Remove and Install Swing Circle Assembly...................................................................................1611 How to Remove Swing Circle Assembly....................................................................................1611 How to Install Swing Circle Assembly...................................................................................1611 Undercarriage and Frame........................................................................................................1613 Separate and Connect Track Assembly........................................................................................1613 How to Separate Track Assembly.........................................................................................1613 How to Install Track Assembly..........................................................................................1615 Remove and Install Sprocket................................................................................................1618 How to Remove Sprocket.................................................................................................1618 How to Install Sprocket................................................................................................1618 Remove and Install Idler and Idler Cushion Assembly........................................................................1620 How to Remove Idler and Idler Cushion Assembly.........................................................................1620 How to Install Idler and Idler Cushion Assembly........................................................................1621 Disassemble and Assemble Idler Assembly....................................................................................1622 How to Disassemble Idler Assembly......................................................................................1622 How to Assemble Idler Assembly.........................................................................................1623 Disassemble and Assemble Idler Cushion Assembly............................................................................1627 How to Disassemble Idler Cushion Assembly..............................................................................1628 How to Assemble Idler Cushion Assembly.................................................................................1628 Disassemble and Assemble Track Roller Assembly.............................................................................1630 How to Disassemble Track Roller Assembly...............................................................................1631 How to Assemble Track Roller Assembly..................................................................................1632 Disassemble and Assemble Carrier Roller Assembly...........................................................................1634 How to Disassemble Carrier Roller Assembly.............................................................................1634 How to Assemble Carrier Roller Assembly................................................................................1635 Remove and Install Revolving Frame Assembly................................................................................1638 How to Remove Revolving Frame Assembly.................................................................................1638 How to Install Revolving Frame Assembly................................................................................1640 Remove and Install Counterweight Assembly..................................................................................1643 How to Remove Counterweight Assembly...................................................................................1643 How to Install Counterweight Assembly..................................................................................1644 Hydraulic System...............................................................................................................1646 Remove and Install Center Swivel Joint Assembly............................................................................1646 How to Remove Center Swivel Joint Assembly.............................................................................1646 How to Install Center Swivel Joint Assembly............................................................................1647 Disassemble and Assemble Center Swivel Joint Assembly......................................................................1650 How to Disassemble Center Swivel Joint Assembly........................................................................1651 How to Assemble Center Swivel Joint Assembly...........................................................................1652 Remove and Install Hydraulic Tank Assembly.................................................................................1653 How to Remove Hydraulic Tank Assembly..................................................................................1653 How to Install Hydraulic Tank Assembly.................................................................................1656 Remove and Install Main Pump Assembly......................................................................................1660 How to Remove Main Pump Assembly.......................................................................................1660 How to Install Main Pump Assembly......................................................................................1664 Remove and Install Control Valve Assembly..................................................................................1668 How to Remove Control Valve Assembly...................................................................................1668 How to Install Control Valve Assembly..................................................................................1672 Disassemble and Assemble Control Valve Assembly............................................................................1676 How to Replace Pressure Compensation Valve Seal Ring...................................................................1677 How to Assemble Control Valve Assembly.................................................................................1678 Disassemble and Assemble Work Equipment PPC Valve Assembly.................................................................1683 How to Disassemble Work Equipment PPC Valve Assembly...................................................................1683 How to Assemble Work Equipment PPC Valve Assembly......................................................................1684 Disassemble and Assemble Travel PPC Valve Assembly.........................................................................1686 How to Disassemble Travel PPC Valve Assembly...........................................................................1686 How to Assemble Travel PPC Valve Assembly..............................................................................1687 Work Equipment.................................................................................................................1689 Remove and Install Work Equipment Assembly.................................................................................1689 How to Remove Work Equipment Assembly..................................................................................1689 How to Install Work Equipment Assembly.................................................................................1691 Disassemble and Assemble Work Equipment Cylinder Assembly..................................................................1693 How to Disassemble Work Equipment Cylinder Assembly....................................................................1693 How to Assemble Work Equipment Cylinder Assembly.......................................................................1698 CAB Related Parts..............................................................................................................1707 Remove and Install Operator Cab Assembly...................................................................................1707 How to Remove Operator Cab Assembly....................................................................................1707 How to Install Operator Cab Assembly...................................................................................1717 Remove and Install Operator Cab Glass (Adhered Glass)......................................................................1728 How to Remove Operator Cab Glass (Adhered Glass).......................................................................1730 How to Install Operator Cab Glass (Adhered Glass)......................................................................1730 Remove and Install Front Window Assembly...................................................................................1740 How to Remove Front Window Assembly....................................................................................1740 How to Install Front Window Assembly...................................................................................1743 Remove and Install Floor Frame Assembly....................................................................................1749 How to Remove Floor Frame Assembly.....................................................................................1749 How to Install Floor Frame Assembly....................................................................................1755 Remove and Install Air Conditioner Unit Assembly...........................................................................1763 How to Remove Air Conditioner Unit Assembly............................................................................1763 How to Install Air Conditioner Unit Assembly...........................................................................1771 Remove and Install Operator Seat...........................................................................................1779 How to Remove Operator Seat............................................................................................1779 How to Install Operator Seat...........................................................................................1780 How to Remove and Install Seat Belt........................................................................................1781 How to Remove Seat Belt................................................................................................1781 How to Install Seatbelt................................................................................................1782 Remove and Install Front Wiper Assembly....................................................................................1783 How to Remove Front Wiper Assembly.....................................................................................1783 How to Install Front Wiper Assembly....................................................................................1788 Electrical System..............................................................................................................1796 Remove and Install Engine Controller Assembly..............................................................................1796 How to Remove Engine Controller Assembly...............................................................................1796 How to Install Engine Controller Assembly..............................................................................1797 Remove and Install Pump Controller Assembly................................................................................1799 How to Remove Pump Controller Assembly.................................................................................1799 How to Install Pump Controller Assembly................................................................................1801 Remove and Install Machine Monitor Assembly................................................................................1805 How to Remove Machine Monitor Assembly.................................................................................1805 How to Install Machine Monitor Assembly................................................................................1808 Remove and Install Gateway Function Controller Assembly....................................................................1812 How to Remove Gateway Function Controller Assembly.....................................................................1812 How to Install Gateway Function Controller Assembly....................................................................1816 Remove and Install Communication Terminal Wiring Harness...................................................................1820 How to Remove Communication Terminal Wiring Harness....................................................................1820 How to Install Communication Terminal Wiring Harness...................................................................1827 Remove and Install Communication Terminal..................................................................................1836 How to Remove Communication Terminal...................................................................................1836 How to Install Communication Terminal..................................................................................1838 60 Maintenance Standard............................................................................................................1841 Table of Contents..............................................................................................................1842 Explanation of Terms for Maintenance Standard..................................................................................1843 Engine and Cooling System......................................................................................................1845 Maintenance Standard for Engine Mount......................................................................................1845 Maintenance Standard for Cooling System....................................................................................1847 Power Train....................................................................................................................1849 Maintenance Standard for Swing Circle......................................................................................1849 Maintenance Standard for Swing Machinery...................................................................................1850 Maintenance Standard for Final Drive.......................................................................................1852 Maintenance Standard for Sprocket..........................................................................................1854 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing.........................................................1855 Undercarriage and Frame........................................................................................................1856 Maintenance Standard for Track Frame and Idler Cushion.....................................................................1856 Maintenance Standard for Idler.............................................................................................1858 Maintenance Standard for Track Roller......................................................................................1860 Maintenance Standard for Carrier Roller....................................................................................1862 Maintenance Standard for Track Shoes.......................................................................................1863 Maintenance Standard for Triple Shoes......................................................................................1866 Hydraulic System...............................................................................................................1867 Maintenance Standard for Hydraulic Tank....................................................................................1867 Maintenance Standard for Main Pump.........................................................................................1868 Maintenance Standard for Swing Motor.......................................................................................1870 Maintenance Standard for Travel Motor......................................................................................1873 Maintenance Standard for Control Valve.....................................................................................1876 Maintenance Standard for Work Equipment and Swing PPC Valve................................................................1887 Maintenance Standard for Travel PPC Valve..................................................................................1890 Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)....................................................1893 Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve........................................................1895 Maintenance Standard for 2nd-Line Attachment PPC Valve.....................................................................1896 Maintenance Standard for Solenoid Valve....................................................................................1898 Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure).............................................1899 Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)..............................................1900 Maintenance Standard for Center Swivel Joint...............................................................................1901 Work Equipment.................................................................................................................1902 Maintenance Standard for Work Equipment Linkage............................................................................1902 Dimensions of Arm..........................................................................................................1905 Dimensions of Bucket.......................................................................................................1908 Maintenance Standard for Boom Cylinder.....................................................................................1911 Maintenance Standard for Arm Cylinder......................................................................................1912 Maintenance Standard for Bucket Cylinder...................................................................................1913 80 Others..........................................................................................................................1915 Table of Contents..............................................................................................................1916 Precautions Before Work........................................................................................................1918 Air Conditioner System.........................................................................................................1919 Precautions for Refrigerant................................................................................................1919 Layout Drawing of Air Conditioner System...................................................................................1920 Specifications of Air Conditioner..........................................................................................1922 Structure of Refrigeration Cycle...........................................................................................1923 Function of Refrigeration Cycle............................................................................................1924 System Diagram of Air Conditioner..............................................................................................1925 Component Parts of Air Conditioner System......................................................................................1926 Air Conditioner Unit.......................................................................................................1926 Structure of Air Conditioner Unit......................................................................................1927 Function of Air Conditioner Unit.......................................................................................1928 Component Parts of Air Conditioner Unit................................................................................1929 Air Conditioner Controller.................................................................................................1933 Structure of Air Conditioner Controller................................................................................1933 Function of Air Conditioner Controller.................................................................................1933 Input and Output Signals of Air Conditioner Controller.................................................................1933 Compressor.................................................................................................................1935 Structure of Compressor................................................................................................1935 Specifications of Compressor...........................................................................................1935 Function of Compressor.................................................................................................1935 Operation of Compressor................................................................................................1935 Condenser..................................................................................................................1936 Structure of Condenser.................................................................................................1936 Specifications of Condenser............................................................................................1936 Function of Condenser..................................................................................................1936 Air Conditioner Related Sensors............................................................................................1938 Structure of Sunlight Sensor...........................................................................................1938 Function of Sunlight Sensor............................................................................................1938 Structure of Outside Temperature Sensor................................................................................1938 Function of Outside Air Temperature Sensor.............................................................................1938 Circuit Diagram and Configuration of Connector Pins of Air Conditioner.........................................................1939 Locations of Air Conditioner Parts and Layout of Connectors....................................................................1941 Examine Air Leakage (Duct Connection)..........................................................................................1945 How to Examine Air Leakage (Duct Connection)...............................................................................1945 Examine Air Conditioner with Self-Diagnosis Function...........................................................................1948 Examine Vent (Mode) Changeover.................................................................................................1949 How to Examine Vent (Mode) Changeover......................................................................................1949 Examine Fresh/Recirc Air Changeover............................................................................................1951 How to Examine Fresh/Recirc Air Changeover.................................................................................1951 Examine Sunlight Sensor........................................................................................................1952 How to Examine Sunlight Sensor.............................................................................................1952 Examine Dual Pressure Switch...................................................................................................1953 How to Examine Dual Pressure Switch........................................................................................1953 Examine Relay..................................................................................................................1954 How to Examine Relay.......................................................................................................1954 Simple Check of Refrigerant Level Through Sight Glass..........................................................................1956 Procedure for Troubleshooting of Air Conditioner...............................................................................1957 Information Shown in Troubleshooting Table.....................................................................................1958 Failure Code [879AKA]..........................................................................................................1961 Failure Code [879AKB]..........................................................................................................1963 Failure Code [879BKA]..........................................................................................................1965 Failure Code [879BKB]..........................................................................................................1968 Failure Code [879CKA]..........................................................................................................1971 Failure Code [879CKB]..........................................................................................................1973 Failure Code [879DKZ]..........................................................................................................1975 Failure Code [879EMC]..........................................................................................................1978 Failure Code [879FMC]..........................................................................................................1980 Failure Code [879GKX]..........................................................................................................1982 Air Conditioner Does Not Operate...............................................................................................1985 Defective Cooling..............................................................................................................1988 Heater Does Not Operate........................................................................................................1997 Cool Air Does Not Come Out.....................................................................................................2001 No Air Comes Out or Air Flow is Abnormal.......................................................................................2007 Fresh/Recirc Air Changeover Does Not Work......................................................................................2011 Connect Service Tool...........................................................................................................2015 How to Connect Service Tool................................................................................................2016 Precautions for Disconnection and Connection of Air Conditioner Piping.........................................................2017 Handle Compressor Oil..........................................................................................................2019 How to Replace Desiccant.......................................................................................................2021 90 Circuit Diagrams................................................................................................................2023 Table of Contents..............................................................................................................2024 How to Read the Codes for Electric Cable.......................................................................................2025 Hydraulic Circuit Diagram......................................................................................................2029 Symbols Used in Hydraulic Circuit Diagram..................................................................................2029 Hydraulic Circuit Diagram..................................................................................................2033 Electrical Circuit Diagram.....................................................................................................2035 Symbols Used in Electric Circuit Diagram...................................................................................2035 Electrical Circuit Diagram (1/6)...........................................................................................2039 Electrical Circuit Diagram (2/6)...........................................................................................2041 Electrical Circuit Diagram (3/6)...........................................................................................2043 Electrical Circuit Diagram (4/6)...........................................................................................2045 Electrical Circuit Diagram (5/6)...........................................................................................2047 Electrical Circuit Diagram (6/6)...........................................................................................2049 Index...............................................................................................................................2051
DESCRIPTION:
KOMATSU PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 PC360-8M2 PC360LC-8M2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06931-03 – PDF DOWNLOAD
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 26/12/24
