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Komatsu PC300LC-5 WITH KDC 614TA ENGINE PC400LC-5 WITH CUMMINS LTA-10C ENGINE Shop Manual PDF
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Komatsu PC300LC-5 WITH KDC 614TA ENGINE PC400LC-5 WITH CUMMINS LTA-10C ENGINE Shop Manual PDF

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Komatsu PC300LC-5 WITH KDC 614TA ENGINE PC400LC-5 WITH CUMMINS LTA-10C ENGINE Excavator Shop Manual – PDF DOWNLOAD

MACHINE MODEL           SERIAL NUMBERS
PC3OOLC-5                         A30001 and up
PC4OOLC-5                         A40001 and up

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Description

Komatsu PC300LC-5 WITH KDC 614TA ENGINE PC400LC-5 WITH CUMMINS LTA-10C ENGINE Excavator Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC300LC-5 WITH KDC 614TA ENGINE PC400LC-5 WITH CUMMINS LTA-10C ENGINE Excavator Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 683
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC300LC-5 WITH KDC 614TA ENGINE PC400LC-5 WITH CUMMINS LTA-10C ENGINE Excavator Shop Manual – PDF DOWNLOAD

MACHINE MODEL           SERIAL NUMBERS
PC3OOLC-5                         A30001 and up
PC4OOLC-5                         A40001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
● Always wear safety glasses when hitting parts with a hammer.
● Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK :

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

TABLE OF CONTENTS:

Komatsu PC300LC-5 WITH KDC 614TA ENGINE PC400LC-5 WITH CUMMINS LTA-10C ENGINE Excavator Shop Manual – PDF DOWNLOAD 

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

S.V 14/12/24 

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