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Komatsu PC300LC-5, PC400LC-5 Hydraulic Excavator Shop Manual CEBM207041 – PDF DOWNLOAD
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Komatsu PC300LC-5, PC400LC-5 Hydraulic Excavator Shop Manual
MACHINE MODEL SERIAL NUMBERS
PC3OOLC-5 A30001 and up
PC4OOLC-5 A40001 and up
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Description
FILE DETAILS:
Komatsu PC300LC-5, PC400LC-5 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC300LC-5, PC400LC-5
Serial Number: A30001 and up, A40001 and up
Book Code: CEBM207041
Language: English
Pages: 683
File Format: Portable Document Format (PDF)
KOMATSU PC300LC-5, PC400LC-5 HYDRAULIC EXCAVATOR SHOP MANUAL CEBM207041 – PDF DOWNLOAD:
DESCRIPTION:
Komatsu PC300LC-5, PC400LC-5 Hydraulic Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC300LC-5, PC400LC-5 Hydraulic Excavator Shop Manual
MAIN MENU......................................................................................................................................................... 0 CONTENTS.......................................................................................................................................................... 9 01 GENERAL....................................................................................................................................................... 19 GENERAL VIEW - PC300LG5, PC400LG5............................................................................................................................. 21 MACHINE DIMENSIONS - PC300LG5................................................................................................................................. 22 WORKING RANGE DIMENSIONS - PC300LC-5.......................................................................................................................... 23 MACHINE SPECIFICATIONS - PC300LG5............................................................................................................................. 24 MACHINE DIMENSIONS - PC400LC-5................................................................................................................................ 26 WORKING RANGE DIMENSIONS - PC400LC-5.......................................................................................................................... 27 MACHINE SPECIFICATIONS - PC400LC-5............................................................................................................................ 28 WEIGHT TABLE.................................................................................................................................................. 30 REFILL SPECIFICATIONS AND CAPACITIES.......................................................................................................................... 32 PC300LC-5................................................................................................................................................. 32 PC400LC-5................................................................................................................................................. 33 10 STRUCTURE AND FUNCTION........................................................................................................................................ 41 ENGINE RELATED PARTS AND ENGINE MOUNT PC300LC ............................................................................................................... 44 ENGINE RELATED PARTS AND ENGINE MOUNT PC400LC ............................................................................................................... 45 RADIATOR AND OIL COOLER PC300LC ............................................................................................................................. 46 RADIATOR AND OIL COOLER PC400LC ............................................................................................................................. 47 FUEL TANK AND PIPING PC300LC ................................................................................................................................ 48 FUEL TANK AND PIPING PC400LC ................................................................................................................................ 49 POWER TRAIN .................................................................................................................................................. 50 FINAL DRIVE PC300LC ......................................................................................................................................... 51 FINAL DRIVE PC400LC ......................................................................................................................................... 52 SWING CIRCLE PC300LC ........................................................................................................................................ 53 SWING CIRCLE PC400LC ........................................................................................................................................ 54 SWING MACHINERY PC300LC ..................................................................................................................................... 55 SWING MACHINERY PC400LC ..................................................................................................................................... 56 TRACK FRAME AND RECOIL SPRING PC300LC ....................................................................................................................... 57 TRACK FRAME AND RECOIL SPRING PC400LC ....................................................................................................................... 58 IDLER PC300LC ............................................................................................................................................... 59 IDLER PC400LC ............................................................................................................................................... 60 TRACK ROLLER ................................................................................................................................................. 61 CARRIER ROLLER ............................................................................................................................................... 61 TRACK SHOE PC300LC .......................................................................................................................................... 62 TRACK SHOE PC400LC .......................................................................................................................................... 63 HYDRAULIC PIPING ............................................................................................................................................. 65 HYDRAULIC CIRCUIT DIAGRAM .................................................................................................................................... 67 HYDRAULIC TANK PC300LC ...................................................................................................................................... 69 HYDRAULIC TANK PC400LC ...................................................................................................................................... 70 OLSS (Open Center Load Sensing System) ....................................................................................................................... 71 HYDRAULIC PUMP ............................................................................................................................................... 73 LINE OIL FILTER .............................................................................................................................................. 92 CONTROL VALVE ................................................................................................................................................ 94 SWING MOTOR ..................................................................................................................................................106 CENTER SWIVEL JOINT ..........................................................................................................................................109 TRAVEL MOTOR PC300LC ........................................................................................................................................110 TRAVEL MOTOR PC400LC ........................................................................................................................................112 VALVE CONTROL ................................................................................................................................................119 PPC VALVE ....................................................................................................................................................120 ACCUMULATOR ..................................................................................................................................................126 SAFETY LOCK VALVE ............................................................................................................................................126 SOLENOID VALVE ASSEMBLY ......................................................................................................................................127 SHUTTLE VALVE ................................................................................................................................................131 BOOM HOLDING VALVE ...........................................................................................................................................132 HYDRAULIC CYLINDER ...........................................................................................................................................135 WORK EQUIPMENT ...............................................................................................................................................138 ELECTRICAL WIRING DIAGRAM PC300LC ...........................................................................................................................140 ELECTRICAL WIRING DIAGRAM PC400LC ...........................................................................................................................142 ELECTRICAL CIRCUIT DIAGRAM PC300LC ..........................................................................................................................145 ELECTRICAL CIRCUIT DIAGRAM PC400LC ..........................................................................................................................149 ENGINE CONTROL SYSTEM PC300LC (S/N A30001 THRU A30110, A30112 AND A30114 THRU A30116)........................................................................153 ENGINE CONTROL SYSTEM PC300LC (S/N A30111, A30113 AND A30117 AND UP).........................................................................................154 ENGINE CONTROL SYSTEM PC400LC ...............................................................................................................................156 PEMC SYSTEM ..................................................................................................................................................168 EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE) ...............................................................................................................197 20 TESTING AND ADJUSTING ........................................................................................................................................207 TABLE OF JUDGEMENT STANDARD VALUE ............................................................................................................................208 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ...................................................................................................................233 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING .............................................................................................................245 ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER .....................................................................................................................246 ADJUSTING ENGINE SPEED SENSOR ................................................................................................................................247 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT ........................................................................248 TESTING AND ADJUSTING CHARGING PUMP PRESSURE .................................................................................................................251 TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE .............................................................................................................253 TESTING AND ADJUSTING TRAVEL DEVIATION .......................................................................................................................260 MEASURING STROKE OF SERVO PISTON .............................................................................................................................263 MEASURING OUTPUT PRESSURE OF PPC VALVE .......................................................................................................................264 ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE .................................................................................................................265 TESTING PPC SHUTTLE VALVE ....................................................................................................................................266 MEASURING SOLENOID VALVE OUTLET PORT PRESSURE ................................................................................................................267 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT .................................................................................................268 BLEEDING AIR .................................................................................................................................................270 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.............................................................................................................272 TROUBLESHOOTING ..............................................................................................................................................273 POINTS TO REMEMBER WHEN TROUBLESHOOTING ..................................................................................................................275 SEQUENCE OF EVENTS IN TROUBLESHOOTING ....................................................................................................................276 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE ................................................................................................................277 HANDLING CONNECTORS - YAZAKI TYPE CONNECTOR...............................................................................................................282 HANDLING CONNECTORS - PACKARD COMPANY CONNECTOR...........................................................................................................283 CHECKS BEFORE TROUBLESHOOTING.............................................................................................................................286 ELECTRICAL CIRCUIT DIAGRAM - ENGINE THROTTLE CONTROLLER SYSTEM (PC300LC)..................................................................................287 ELECTRICAL CIRCUIT DIAGRAM - ENGINE THROTTLE CONTROLLER SYSTEM (PC400LC)..................................................................................288 PUMP CONTROLLER SYSTEM - PC300LC..........................................................................................................................289 PUMP CONTROLLER SYSTEM - PC400LC..........................................................................................................................290 MONITOR SYSTEM - PC300LC..................................................................................................................................291 MONITOR SYSTEM - PC400LC..................................................................................................................................292 POSITION OF CONNECTORS FOR TROUBLESHOOTING TABLE - PC300LC ...............................................................................................293 POSITION OF CONNECTORS FOR TROUBLESHOOTING - PC300LC .....................................................................................................295 POSITION OF CONNECTORS FOR TROUBLESHOOTING TABLE - PC400LC ...............................................................................................297 POSITION OF CONNECTORS FOR TROUBLESHOOTING - PC400LC .....................................................................................................299 CONNECTION TABLE FOR CONNECTOR (N-SLC TYPE)...............................................................................................................301 CONNECTION TABLE FOR CONNECTOR (M TYPE)...................................................................................................................302 CONNECTION TABLE FOR CONNECTOR (S TYPE)...................................................................................................................304 CONNECTION TABLE FOR CONNECTOR (AMP040 TYPE)..............................................................................................................305 CONNECTION TABLE FOR CONNECTOR (SWP TYPE).................................................................................................................306 CONNECTION TABLE FOR CONNECTOR (MIC TYPE).................................................................................................................307 CONNECTION TABLE FOR CONNECTOR (X TYPE)...................................................................................................................308 CONNECTION TABLE FOR CONNECTOR ...........................................................................................................................309 EXPLANATION OF THE FUNCTIONS OF THE CONTROL MECHANISM OF THE ELECTRICAL SYSTEM ..........................................................................310 DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER ........................................................................313 ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTONS ON MACHINE - ENGINE THROTTLE CONTROLLER SYSTEM..........................................................317 ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE - PUMP CONTROLLER SYSTEM......................................................................319 METHOD OF USING JUDGEMENT TABLE ..........................................................................................................................323 METHOD OF USING TROUBLESHOOTING CHARTS ...................................................................................................................325 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E-MODE)......................................................................................................327 ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS ................................................................................................329 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM ...........................................................331 E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF) ..................................................................332 E-2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAYED. ..................................................................................................334 E-3 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED..................................................................................335 E-4 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED..............................................................................................336 E-5 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED ..................................................................................................338 E-6 [ABNORMALITY IN NO.2 THROTTLE SIGNAL] IS DISPLAYED................................................................................................340 E-7 ENGINE DOES NOT START ............................................................................................................................342 E-7 ENGINE DOES NOT START (PC300LC)...................................................................................................................344 E-7 ENGINE DOES NOT START (PC400LC)...................................................................................................................345 E-8 ENGINE ROTATION IS IRREGULAR .....................................................................................................................346 E-9 LACK OF OUTPUT POWER (MAX. ENGINE SPEED IS TOO LOW) ..............................................................................................350 E-10 ENGINE DOES NOT STOP (PC300LC)...................................................................................................................352 E-10 ENGINE DOES NOT STOP (PC400LC)...................................................................................................................353 E-l 1 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE ....................................................................................................354 TROUBLESHOOTING OF PUMP SYSTEM (C MODE)...................................................................................................................355 CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS .............................................................357 C-1 [OFF] SELF-DIAGNOSTIC DISPLAY OF CONTROLLER DOES NOT LIGHT UP.....................................................................................359 C-2 [SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID VALVE SYSTEM] IS DISPLAYED .............................................................................360 C-3 [SHORT CIRCUIT IN ARM HALF FLOW SOLENOID VALVE SYSTEM] IS DISPLAYED..............................................................................361 C-4 [SHORT CIRCUIT IN SWING BRAKE SOLENOID VALVE SYSTEM] IS DISPLAYED.................................................................................362 C-5 [SHORT CIRCUIT IN TRAVEL SPEED SOLENOID VALVE SYSTEM] IS DISPLAYED................................................................................363 C-6 [SHORT CIRCUIT IN CO CANCEL SOLENOID VALVE SYSTEM] IS DISPLAYED...................................................................................364 C-7 [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (1)] IS DISPLAYED ..........................................................................................365 C-8 [SHORT CIRCUIT IN TVC SOLENOID VALVE SYSTEM (2)] IS DISPLAYED.....................................................................................366 C-9 [DISCONNECTION IN 2-STAGE RELIEF SOLENOID VALVE SYSTEM] IS DISPLAYED..............................................................................367 C-10 [DISCONNECTION IN ARM HALF FLOW SOLENOID VALVE SYSTEM] IS DISPLAYED..............................................................................368 C-11 [DISCONNECTION IN SWING BRAKE SOLENOID VALVE SYSTEM] IS DISPLAYED...............................................................................369 C-12 [DISCONNECTION IN TRAVEL SPEED SOLENOID VALVE SYSTEM] IS DISPLAYED...............................................................................370 C-13 [DISCONNECTION IN CO CANCEL SOLENOID VALVE SYSTEM] IS DISPLAYED..................................................................................371 C-14 [DISCONNECTION IN TVC SOLENOID VALVE SYSTEM] IS DISPLAYED .......................................................................................372 C-15 [ABNORMALITY IN NO.2 THROTTLE SIGNAL SYSTEM] IS DISPLAYED .......................................................................................373 C-16 [ ABNORMALITY IN THROTTLE SIGNAL SYSTEM] IS DISPLAYED ...........................................................................................374 C-17 [ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SIGNAL SYSTEM] IS DISPLAYED...........................................................................376 C-18 [ABNORMALITY IN REAR PUMP PRESSURE SENSOR SIGNAL SYSTEM] IS DISPLAYED............................................................................378 C-19 [ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM] IS DISPLAYED................................................................................380 C-20 [ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM] IS DISPLAYED ........................................................................................382 C-21 [ABNORMALITY IN AUTO-DECELERATION SIGNAL OUTPUT SYSTEM] IS DISPLAYED.............................................................................383 C-22 [ABNORMALITY IN OVERHEAT SIGNAL SYSTEM] IS DISPLAYED ............................................................................................384 C-23 [CONTROLLER ABNORMAL SYSTEM] IS DISPLAYED........................................................................................................385 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE).........................................................................................387 F-1 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [WORK EQUIPMENT • SWING OIL PRESSURE SWITCH].............................................................388 F-2 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [TRAVEL OIL PRESSURE SWITCH].............................................................................389 F-3 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [SWING LOCK SWITCH]......................................................................................390 F-4 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [TRAVEL SPEED SWITCH]....................................................................................391 F-5 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [AUTO-DECELERATION SWITCH]...............................................................................392 F-6 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [POWER MAXIMIZING SWITCH]................................................................................393 F-7 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [DECIMAL POINT OF ENGINE SPEED SENSOR]..................................................................394 F-8 PUMP CONTROLLER WORKING MODE DISPLAY DOES NOT SWITCH.............................................................................................395 F-9 PUMP CONTROLLER POWER SET DISPLAY DOES NOT SWITCH ................................................................................................396 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...............................................................................................397 H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL AND SWING ARE ALL SLOW .........................................................................................398 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED OR ENGINE STALLS .........................................................................................400 H-3 WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE OR SPEED IS EXTREMELY SLOW ..........................................................................402 H-4 WORK EQUIPMENT, TRAVEL AND SWING LACK POWER ......................................................................................................404 H-5 POWER SET SELECTION SYSTEM DOES NOT SWITCH........................................................................................................404 H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP) ......................................................................................................405 H-7 AUTO-DECELERATION DOES NOT WORK ..................................................................................................................405 H-8 BOOM AND ARM SPEED IS EXTREMELY SLOW .............................................................................................................406 H-9 WORK EQUIPMENT (BOOM, ARM AND BUCKET) SPEED IS SLOW ..............................................................................................408 H-10 WHEN BOOM AND ARM IS OPERATED SIMULTANEOUSLY, BOOM IS SLOW......................................................................................410 H-11 WORK EQUIPMENT (BOOM, ARM AND BUCKET) LACKS POWER ...............................................................................................410 H-12 EXCESSIVE HYDRAULIC DRIFT .......................................................................................................................410 H-13 EXCESSIVE TIME LAG ..............................................................................................................................412 H-14 DOES NOT ENTER F.O. MODE (HALF FLOW FUNCTION) ...................................................................................................412 H-15 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY, ARM IS SLOW ....................................................................................412 H-16 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE ....................................................................................414 H-17 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS ..................................................................................................417 H-18 EXCESSIVE DEVIATION WHEN STARTING ...............................................................................................................418 H-I9 TRAVEL LACKS POWER (OR SPEED IS SLOW) ...........................................................................................................420 H-20 TRAVEL SPEED DOES NOT SWITCH ....................................................................................................................420 H-21 MACHINE DOES NOT MOVE (ONE SIDE ONLY) ...........................................................................................................421 H-22 DOES NOT SWING ..................................................................................................................................422 H-23 SWING SPEED IS SLOW OR ACCELERATION IS POOR .....................................................................................................424 H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING ...........................................................................................................425 H-25 EXCESSIVE SHOCK WHEN STOPPING SWING .............................................................................................................425 H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING ....................................................................................................426 H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING ..............................................................................................................426 H-28 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW ......................................................................................426 TABLE OF FAILURE MODES AND CAUSES ....................................................................................................................427 TROUBLESHOOTING OF MONITOR SYSTEM (P-MODE)................................................................................................................429 P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON .............................................................431 P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON BUT DO NOT GO OUT ............................................................432 P-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH (LEVELS FOR CHECK ITEMS ARE AS SPECIFIED) ................................433 P-4 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH ......................................................................436 P-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH .........................................................................437 P-6 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE) ...........438 P-7(a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND....441 P-7(b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR BUT THE BUZZER SOUNDS ..........................................................................441 P-8 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL) .............................................................442 P-9 COOLANT TEMPERATURE SHOWS ABNORMALITY LOW TEMPERATURE ..........................................................................................443 P-10 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING OPERATION, NO LEVEL OF GAUGE IS DISPLAYED)...................................................443 P-11 FUEL GAUGE ALWAYS DISPLAYS FULL .................................................................................................................444 P-12 FUEL GAUGE GIVES NO DISPLAY .....................................................................................................................444 P-13(a) LAMPS DO NOT LIGHT UP ........................................................................................................................446 P-13(b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NOT OPERATED ........................................................................................446 P-14(a) WIPERS DO NOT WORK ...........................................................................................................................448 P-14(b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED ..........................................................................................448 P-15(a) FAN DOES NOT WORK ............................................................................................................................450 P-15(b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED................................................................................................450 P-16 WORKING MODE DOES NOT SWITCH ....................................................................................................................452 P-17 POWER SET DOES NOT SWITCH .......................................................................................................................453 P-18 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION: AUTO-DECELERATION IS NOT CANCELED) .......................................454 P-19 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO ..................................................................................................455 P-20 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 3O”C, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30°C .............456 P-21 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP .............................................457 P-22 FUEL LEVEL SENSOR SYSTEM DEFECTIVE ..............................................................................................................458 P-23 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE .....................................................................................................459 P-24 ENGINE OIL LEVEL SENSOR SYSTEM DEFECTIVE.........................................................................................................460 P-25 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE ...........................................................................................................461 P-26 HYDRAULIC OIL LEVEL SENSOR SYSTEM DEFECTIVE .....................................................................................................462 30 DISASSEMBLY AND ASSEMBLY......................................................................................................................................463 METHOD OF USING MANUAL .......................................................................................................................................467 PRECAUTIONS WHEN CARRYING OUT OPERATION ......................................................................................................................468 SPECIAL TOOL LIST PC300LC ....................................................................................................................................470 SPECIAL TOOL LIST PC400LC ....................................................................................................................................473 WEIGHT TABLE .................................................................................................................................................476 TIGHTENING TORQUES AND STANDARD VALUES TABLE .................................................................................................................477 LUBRICANT AND COOLANT TABLE ..................................................................................................................................483 REMOVAL OF GOVERNOR MOTOR ASSEMBLY ...........................................................................................................................484 REMOVAL OF HYDRAULIC COOLER ASSEMBLY..........................................................................................................................486 INSTALLATION OF HYDRAULIC COOLER ASSEMBLY ....................................................................................................................486 REMOVAL OF HYDRAULIC COOLER ASSEMBLY..........................................................................................................................486 INSTALLATION OF HYDRAULIC COOLER ASSEMBLY ....................................................................................................................486 REMOVAL OF RADIATOR, HYDRAULIC OIL COOLER ....................................................................................................................488 INSTALLATION OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY.......................................................................................................488 REMOVAL OF ENGINE, HYDRAULIC PUMP ASSEMBLY....................................................................................................................490 INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMBLY...............................................................................................................490 REMOVAL OF ENGINE, HYDRAULIC PUMP ASSEMBLY ..................................................................................................................492 INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMBLY .............................................................................................................492 REMOVAL OF DAMPER ASSEMBLY ..................................................................................................................................494 INSTALLATION OF DAMPER ASSEMBLY .............................................................................................................................494 REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY.......................................................................................................................496 INSTALLATION OF CENTER ASSEMBLY SWIVEL JOINT................................................................................................................496 DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY...................................................................................................................496 ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY ....................................................................................................................496 REMOVAL OF FINAL DRIVE DRIVE ASSEMBLY ........................................................................................................................498 INSTALLATION OF FINAL DRIVE ASSEMBLY..........................................................................................................................498 DISASSEMBLY OF FINAL DRIVE ASSEMBLY ..........................................................................................................................498 ASSEMBLY OF FINAL DRIVE ASSEMBLY ............................................................................................................................502 DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMV280ADT) (HMV355ADT) .................................................................................................506 ASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMV280ADT) (HMV355ADT) ....................................................................................................511 REMOVAL OF SPROCKET...........................................................................................................................................520 INSTALLATION OF SPROCKET......................................................................................................................................520 REMOVAL OF SWING MOTOR ASSEMBLY .............................................................................................................................520 INSTALLATION OF SWING MOTOR ASSEMBLY .........................................................................................................................520 DISASSEMBLY OF SWING MOTOR ASSEMBLY (KMF160) .................................................................................................................522 ASSEMBLY OF SWING MOTOR ASSEMBLY (KMFI 60) ..................................................................................................................525 REMOVAL OF SWING MACHINERY ASSEMBLY..........................................................................................................................530 INSTALLATION OF SWING MACHINERY ASSEMBLY.....................................................................................................................530 REMOVAL OF SWING MACHINERY ASSEMBLY...........................................................................................................................530 INSTALLATION OF SWING MACHINERY ASSEMBLY ....................................................................................................................530 DISASSEMBLY OF SWING MACHINERY ASSEMBLY .....................................................................................................................532 ASSEMBLY OF SWING MACHINERY ASSEMBLY ........................................................................................................................534 REMOVAL OF REVOLVING FRAME ASSEMBLY .........................................................................................................................540 INSTALLATION OF REVOLVING FRAME ASSEMBLY ....................................................................................................................540 REMOVAL OF SWING CIRCLE ASSEMBLY .............................................................................................................................542 INSTALLATION OF SWING CIRCLE ASSEMBLY........................................................................................................................542 REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY.....................................................................................................................542 INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY ...............................................................................................................542 DISASSEMBLY OF RECOIL SPRING ASSEMBLY.........................................................................................................................544 ASSEMBLY OF RECOIL SPRING ASSEMBLY...........................................................................................................................544 REMOVAL OF TRACK ROLLER ASSEMBLY..............................................................................................................................546 INSTALLATION OF TRACK ROLLER ASSEMBLY .......................................................................................................................546 REMOVAL OF CARRIER ROLLER ASSEMBLY............................................................................................................................546 INSTALLATION OF CARRIER ROLLER ASSEMBLY.......................................................................................................................546 REMOVAL OF TRACK SHOE ASSEMBLY................................................................................................................................548 INSTALLATION OF TRACK SHOE ASSEMBLY...........................................................................................................................548 REMOVAL OF CHARGING PUMP ASSEMBLY.............................................................................................................................548 INSTALLATION OF CHARGING PUMP ASSEMBLY ......................................................................................................................548 REMOVAL OF HYDRAULIC PUMP ASSEMBLY ...........................................................................................................................550 INSTALLATION OF HYDRAULIC PUMP ASSEMBLY.......................................................................................................................550 REMOVAL OF HYDRAULIC PUMP ASSEMBLY...........................................................................................................................550 DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY (HPV160+160) ..........................................................................................................552 ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY (HPV160+160) .............................................................................................................559 CHECKING CONTACT BETWEEN CYLINDER BLOCKAND VALVE PLATE, AND ROCKER CAM AND CRADLE............................................................................573 REMOVAL OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL ..............................................................................................................576 INSTALLATION OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL .........................................................................................................576 REMOVAL OF CONTROL VALVE ASSEMBLY.............................................................................................................................578 INSTALLATION OF CONTROL VALVE ASSEMBLY........................................................................................................................578 DISASSEMBLY OF CONTROL VALVE ASSEMBLY .......................................................................................................................580 ASSEMBLY OF CONTROL VALVE ASSEMBLY ..........................................................................................................................582 REMOVAL OF MAIN RELIEF VALVE ASSEMBLY ........................................................................................................................584 INSTALLATION OF MAIN RELIEF VALVE ASSEMBLY...................................................................................................................584 DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY....................................................................................................................584 ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY ......................................................................................................................584 REMOVAL OF TVC VALVE ASSEMBLY.................................................................................................................................586 INSTALLATION OF TVC VALVE ASSEMBLY ...........................................................................................................................586 REMOVAL OF CO•NC VALVE ASSEMBLY .............................................................................................................................586 INSTALLATION OF CO•NC VALVE ASSEMBLY ........................................................................................................................586 REMOVAL OF SERVO VALVE ASSEMBLY...............................................................................................................................586 INSTALLATION OF SERVO VALVE ASSEMBLY..........................................................................................................................586 REMOVAL OF WORK EQUIPMENT PPC VALVE ASSEMBLY ...............................................................................................................588 INSTALLATION OF WORK EQUIPMENT PPC VALVE ASSEMBLY ..........................................................................................................588 DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY ...........................................................................................................588 ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY ..............................................................................................................588 REMOVAL OF TRAVEL PPC VALVE ASSEMBLY..........................................................................................................................590 INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY.....................................................................................................................590 DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY.....................................................................................................................590 ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY ........................................................................................................................590 REMOVAL OF BOOM HOLDING VALVE ASSEMBLY.......................................................................................................................592 INSTALLATION OF BOOM HOLDING VALVE ASSEMBLY...................................................................................................................592 DISASSEMBLY OF BOOM HOLDING VALVE ASSEMBLY....................................................................................................................592 ASSEMBLY OF BOOM HOLDING VALVE ASSEMBLY.......................................................................................................................592 REMOVAL OF PPC SHUTTLE VALVE ASSEMBLY.........................................................................................................................594 INSTALLATION OF PPC SHUTTLE VALVE ASSEMBLY....................................................................................................................594 REMOVAL OF BOOM CYLINDER ASSEMBLY ............................................................................................................................596 INSTALLATION OF BOOM CYLINDER ASSEMBLY........................................................................................................................596 REMOVAL OF ARM CYLINDER ASSEMBLY..............................................................................................................................598 INSTALLATION OF ARM CYLINDER ASSEMBLY.........................................................................................................................598 REMOVAL OF BUCKET CYLINDER ASSEMBLY...........................................................................................................................600 INSTALLATION OF BUCKET CYLINDER ASSEMBLY......................................................................................................................600 DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY....................................................................................................................602 ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY .....................................................................................................................604 REMOVAL OF WORK EQUIPMENT ASSEMBLY............................................................................................................................606 INSTALLATION OF WORK EQUIPMENT ASSEMBLY.......................................................................................................................606 REMOVAL OF BUCKET ASSEMBLY ...................................................................................................................................608 INSTALLATION OF BUCKET ASSEMBLY..............................................................................................................................608 REMOVAL OF ARM ASSEMBLY.......................................................................................................................................608 INSTALLATION OF ARM ASSEMBLY .................................................................................................................................608 REMOVAL OF ARM, BUCKET ASSEMBLY...............................................................................................................................610 INSTALLATION OF ARM, BUCKET ASSEMBLY..........................................................................................................................610 REMOVAL OF BOOM ASSEMBLY......................................................................................................................................612 INSTALLATION OF BOOM ASSEMBLY.................................................................................................................................612 REMOVAL OF OPERATOR’S CAB ASSEMBLY............................................................................................................................614 INSTALLATION OF OPERATOR’S CAB ASSEMBLY ......................................................................................................................614 REMOVAL OF COUNTERWEIGHT .....................................................................................................................................614 INSTALLATION OF COUNTERWEIGHT ................................................................................................................................614 REMOVAL OF ENGINE THROTTLE CONTROLLER.........................................................................................................................616 INSTALLATION OF ENGINE THROTTLE CONTROLLER ...................................................................................................................616 REMOVAL OF PUMP CONTROLLER ASSEMBLY ..........................................................................................................................616 INSTALLATION OF PUMP CONTROLLER ASSEMBLY .....................................................................................................................616 REMOVAL OF MONITOR PANEL ASSEMBLY.............................................................................................................................616 INSTALLATION OF MONITOR PANEL ASSEMBLY ......................................................................................................................616 PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT .....................................................................................................................618 PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT......................................................................................................................626 40 MAINTENANCE STANDARD..........................................................................................................................................635 FINAL DRIVE PC300LC...........................................................................................................................................638 FINAL DRIVE PC400LC...........................................................................................................................................640 SWING MACHINERY PC300LC.......................................................................................................................................642 SWING MACHINERY PC400LC.......................................................................................................................................644 SWING CIRCLE PC300LC..........................................................................................................................................646 SWING CIRCLE PC400LC..........................................................................................................................................647 TRACK FRAME AND RECOIL SPRING PC300LC.........................................................................................................................648 TRACK FRAME AND RECOIL SPRING PC400LC.........................................................................................................................649 IDLER PC300LC.................................................................................................................................................650 IDLER PC400LC.................................................................................................................................................652 TRACK ROLLER PC300LC..........................................................................................................................................654 TRACK ROLLER PC400LC..........................................................................................................................................655 CARRIER ROLLER ...............................................................................................................................................656 TRACK SHOE PC300LC............................................................................................................................................658 TRACK SHOE PC400LC............................................................................................................................................660 CHARGING PUMP AND RELIEF VALVE ...............................................................................................................................662 CONTROL VALVE ................................................................................................................................................663 TRAVEL SHUTTLE VALVE .........................................................................................................................................670 SWING MOTOR ..................................................................................................................................................671 TRAVEL MOTOR PC300LC..........................................................................................................................................672 TRAVEL MOTOR PC400LC..........................................................................................................................................673 PPC VALVE, FOR WORK EQUIPMENT AND SWING.......................................................................................................................674 PPC VALVE, FOR TRAVEL.........................................................................................................................................675 PPC SHUTTLE VALVE ............................................................................................................................................676 BOOM HOLDING VALVE ...........................................................................................................................................677 HYDRAULIC CYLINDER PC300LC....................................................................................................................................678 HYDRAULIC CYLINDER PC400LC....................................................................................................................................679 WORK EQUIPMENT PC300LC........................................................................................................................................680 WORK EQUIPMENT PC400LC........................................................................................................................................682
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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