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KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A80001 and up) – PDF DOWNLOAD
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- KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER: A80001 and up
- PUBLICATION NUMBER:CEBM3006C2
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Description
KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A80001 and up)
KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A80001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A80001 and up)
- 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 sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A80001 and up)
MAIN MENU........................................................................................................................................... 0 CONTENTS............................................................................................................................................ 2 00 SAFETY/FOREWARD.................................................................................................................................. 9 01 GENERAL.......................................................................................................................................... 24 SPECIFICATION DRAWINGS.......................................................................................................................... 25 PC300LC-6................................................................................................................................... 25 PC300HD-6................................................................................................................................... 27 SPECIFICATIONS.................................................................................................................................. 29 PC300LC-6................................................................................................................................... 29 PC300HD-6................................................................................................................................... 29 WEIGHT TABLE.................................................................................................................................... 31 PC300LC-6................................................................................................................................... 31 PC300HD-6................................................................................................................................... 31 FUEL, COOLANT AND LUBRICANTS.................................................................................................................... 33 PC300LC-6................................................................................................................................... 33 PC300HD-6................................................................................................................................... 34 ENGINE OIL SPECIFICATIONS....................................................................................................................... 35 DIESEL FUEL SPECIFICATIONS...................................................................................................................... 36 COOLANT SPECIFICATIONS.......................................................................................................................... 37 10 STRUCTURE AND FUNCTION .......................................................................................................................... 43 ENGINE RELATED PARTS ........................................................................................................................... 44 RADIATOR OIL COOLER ............................................................................................................................ 46 POWER TRAIN .................................................................................................................................... 47 FINAL DRIVE PC300LC-6........................................................................................................................... 48 FINAL DRIVE PC300HD-6........................................................................................................................... 49 SWING CIRCLE ................................................................................................................................... 50 SWING MACHINERY ................................................................................................................................ 51 TRACK FRAME RECOIL SPRING ...................................................................................................................... 52 TRACK SHOE ..................................................................................................................................... 54 HYDRAULIC PIPING DRAWING ....................................................................................................................... 55 HYDRAULIC CIRCUIT DIAGRAM ...................................................................................................................... 56 HYDRAULIC TANK.................................................................................................................................. 57 HYDRAULIC PUMP ................................................................................................................................. 58 CONTROL PUMP.................................................................................................................................... 77 SUCTION SAFETY VALVE ........................................................................................................................... 88 CLSS ........................................................................................................................................... 89 SWING MOTOR ....................................................................................................................................131 CENTER SWIVEL JOINT ............................................................................................................................135 TRAVEL MOTOR ...................................................................................................................................136 VALVE CONTROL ..................................................................................................................................151 WORK EQUIPMENT SWING PPC VALVE .................................................................................................................152 TRAVEL PPC VALVE ...............................................................................................................................156 SERVICE PPC VALVE ..............................................................................................................................160 PPC SAFETY LOCK VALVE...........................................................................................................................163 PPC ACCUMULATOR.................................................................................................................................163 PPC SHUTTLE VALVE TRAVEL JUNCTION VALVE ........................................................................................................164 EPC SOLENOID VALVE .............................................................................................................................171 FOR LS SELECT, BOOM HI 2-STAGE SAFETY VALVE, MERGE/FLOW DIVIDER, TRAVEL SPEED, SWING BRAKE......................................................171 FOR LS VALVE CONTROL............................................................................................................................173 BOOM HOLDING VALVE .............................................................................................................................176 HYDRAULIC CYLINDER .............................................................................................................................179 WORK EQUIPMENT .................................................................................................................................180 ELECTRICAL WIRING DIAGRAM ......................................................................................................................181 ELECTRICAL CIRCUIT DIAGRAM......................................................................................................................183 ENGINE CONTROL .................................................................................................................................186 ELECTRONIC CONTROL SYSTEM ......................................................................................................................192 MACHINE MONITOR SYSTEM..........................................................................................................................215 20 TESTING AND ADJUSTMENT...........................................................................................................................222 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................223 STANDARD VALUE TABLE FOR CHASSIS PARTS..........................................................................................................224 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.......................................................................................................232 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING................................................................................................240 MEASURING ENGINE SPEED..........................................................................................................................241 MEASURING INTAKE MANIFOLD PRESSURE..............................................................................................................242 MEASURING INTAKE AIR RESTRICTION................................................................................................................243 MEASURING LUBRICATING OIL PRESSURE..............................................................................................................244 MEASURING FUEL (FILTER) INLET RESTRICTION.......................................................................................................245 MEASURING BLOWBY PRESSURE.......................................................................................................................246 MEASURING ENGINE BACK PRESSURE..................................................................................................................247 MEASURING EXHAUST COLOR.........................................................................................................................248 MEASURING COOLANT TEMPERATURE...................................................................................................................249 MEASURING VALVE CLEARANCE.......................................................................................................................250 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE...............................................................................................251 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................................................252 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...................................................................255 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE.......................................257 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE.........................................................................................260 TESTING SOLENOID VALVE OUTPUT PRESSURE..........................................................................................................262 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...............................................................................264 ADJUSTING WORK EQUIPMENT SWING PPC VALVE........................................................................................................266 TESTING TRAVEL DEVIATION........................................................................................................................267 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................................................268 MEASURING OIL LEAKAGE...........................................................................................................................270 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................272 TESTING CLEARANCE OF SWING CIRCLE BEARING.......................................................................................................273 TESTING AND ADJUSTING TRACK SHOE TENSION........................................................................................................274 BLEEDING AIR....................................................................................................................................275 TROUBLESHOOTING.................................................................................................................................277 TROUBLESHOOTING.............................................................................................................................277 POINTS TO REMEMBER WHEN TROUBLESHOOTING ................................................................................................278 SEQUENCE OF EVENTS IN TROUBLESHOOTING ..................................................................................................279 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE .......................................................................................280 CHECKS BEFORE TROUBLESHOOTING ..........................................................................................................289 CONNECTOR TYPES AND MOUNTING LOCATIONS .................................................................................................290 CONNECTOR ARRANGEMENT DIAGRAM...........................................................................................................292 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..............................................................................................294 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM .................................................................................305 DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL ................................................................................306 METHOD OF USING JUDGEMENT TABLE ........................................................................................................314 METHOD OF USING TROUBLSHOOTING CHARTS ..................................................................................................316 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE ...............................................................................318 SERVICE CODE TABLE .....................................................................................................................323 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)................................................................................324 N-1 [E218] Communication abnormality....................................................................................................325 TROUBLESHOOTING OF GOVERNOR PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (N MODE)..............................................................327 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM................................................328 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.............................................................329 JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND RELATED PARTS.................................................333 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM............................................................................................335 E-1 Abnormality in governor, pump controller power source (controller LED is OFF)...................................................337 E-2 [E308] Abnormality in fuel control dial input value is displayed................................................................338 E-3 [317] Abnormality (disconnection) in motor drive system is displayed............................................................339 E-4 [318] Abnormality (short circuit) in motor drive system is displayed............................................................340 E-5 [E306] Abnormality in feedback potentiometer system is displayed................................................................341 E-6 [E315] Abnormality (short circuit) in battery relay output system is displayed..................................................342 E-7 [E316] Abnormality (step-out) in motor displayed................................................................................343 E-8 Engine does not start...........................................................................................................344 E-9 Engine speed is irregular.......................................................................................................346 E-10 Lack of output (engine high idling speed is to low)............................................................................350 E-11 Engine does not stop...........................................................................................................352 E-12 Defective operation of battery relay system (engine does not stop).............................................................354 TROUBLESHOOTING OF ENGINE SYSTEM............................................................................................................356 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................................357 S-1 Starting performance is poor (starting always takes time)...........................................................................361 S-2 Engine does not start...............................................................................................................362 S-3 Engine does not pick up smoothly (follow up is poor)................................................................................365 S-4 Engine stops during operations......................................................................................................366 S-5 Engine does not rotate smoothly (hunting)...........................................................................................367 S-6 Engine lacks output (no power)......................................................................................................368 S-7 Engine smoke is black (incomplete combustion).......................................................................................369 S-8 Oil consumption is excessive (or exhaust smoke is blue).............................................................................370 S-9 Oil becomes contaminated quickly....................................................................................................371 S-10 Fuel consumption is excessive......................................................................................................372 S-11 Oil is in cooling water, or water spurts back, or water level goes down............................................................373 S-12 Oil pressure caution lamp lights up (drop in oil pressure).........................................................................374 S-13 Oil level rises (water, fuel in oil)...............................................................................................375 S-14 Water temperature becomes too high (overheating)...................................................................................376 S-15 Abnormal noise is made.............................................................................................................377 S-16 Vibration is excessive.............................................................................................................378 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE).................................................................379 POINT TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...........................................................................380 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..............................................................381 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.........................................387 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE...................................................................................................389 C-1 Abnormality in controller power source system (controller LED is OFF)...........................................................391 C-2 [E232] Short circuit in front pump TVC solenoid system is displayed.............................................................392 C-3 [E233] Disconnection in front pump TVC solenoid system is displayed.............................................................394 C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed..............................................................396 C-5 [E237] Disconnection in rear pump WC solenoid system is displayed...............................................................398 C-6 [E202] Short circuit in LS select solenoid system is displayed..................................................................400 C-7 [E212] Disconnection in LS select solenoid system is displayed..................................................................401 C-8 [E203] Short circuit in swing brake solenoid system is displayed................................................................402 C-9 [E213] Disconnection in swing brake solenoid system is displayed................................................................404 C-10 [E204] Short circuit in pump merge/divider solenoid system is displayed........................................................406 C-11 [E214] Disconnection in pump merge/divider solenoid system is displayed........................................................407 C-12 [E206] Short circuit in travel speed solenoid system is displayed..............................................................408 C-13 [E216] Disconnection in travel speed selector solenoid system is displayed.....................................................409 C-14 [E217] Model selection input error is displayed ...............................................................................410 C-15 [E222] Short circuit in LS-EPC solenoid system is displayed....................................................................412 C-16 [E223] Disconnection in LS-EPC solenoid system is displayed....................................................................413 C-17 [E224] Abnormality in front pump pressure sensor system is displayed...........................................................414 C-18 [E225] Abnormality in rear pump pressure sensor system is displayed............................................................415 C-19 [E226] Abnormality in pressure sensor power source system is displayed.........................................................416 C-20 [E227] Abnormality in engine speed sensor system is displayed..................................................................417 C-21 Abnormality in machine push up solenoid system (no service code displayed).....................................................418 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)....................................................................................433 PUMP MERGE/DIVIDER LOGIC................................................................................................................434 LS SELECT LOGIC.........................................................................................................................435 SOLENOID ACTUATION TABLE................................................................................................................435 TABLE OF FAILURE MODES AND CAUSES.......................................................................................................436 H-1 Speeds of all work equipment, swing, travel are slow or lack power..............................................................440 H-2 There is excessive drop in engine speed, or engine stalls.......................................................................442 H-3 No work equipment, travel, swing move...........................................................................................443 H-4 Abnormal noise generated (around pump)..........................................................................................443 H-5 Auto-deceleration does not work (when PPC shuttle valve is cause)...............................................................444 H-6 Fine control ability is poor or response is poor................................................................................445 H-7 Boom is slow or lacks power.....................................................................................................446 H-8 Arm is slow or lacks power......................................................................................................448 H-9 Bucket is slow or lacks power...................................................................................................450 H-10 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal).............................................451 H-11 Excessive hydraulic drift (boom, arm, bucket)..................................................................................451 H-12 Excessive time lag (engine at low idling)......................................................................................452 H-13 Other equipment moves when single circuit is relieved..........................................................................452 H-14 In L/O, F/O modes, work equipment speed is faster than specified speed.........................................................453 H-15 Defective actuation of machine push-up function................................................................................453 H-16 In compound operations, work equipment with larger load is slow................................................................453 H-17 In swing + boom RAISE, boom RAISE is slow......................................................................................454 H-18 In swing + arm, arm is slow....................................................................................................454 H-19 In swing + travel, travel speed drops excessively..............................................................................454 H-20 Travel deviation...............................................................................................................455 H-21 Travel speed is slow...........................................................................................................456 H-22 Steering does not turn easily or lacks power...................................................................................458 H-23 Travel speed does not switch or is faster than specified speed.................................................................460 H-24 Travel speed does not switch or is faster than specified speed.................................................................460 H-25 Does not swing.................................................................................................................461 H-26 Swing acceleration is poor or swing speed is slow..............................................................................462 H-27 Excessive overrun when stopping swing..........................................................................................464 H-28 Excessive shock when stopping swing (one direction only).......................................................................465 H-29 Excessive abnormal noise when stopping swing...................................................................................465 H-30 Excessive hydraulic drift of swing.............................................................................................466 H-31 Swing speed is faster than specified swing speed...............................................................................467 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE).................................................................420 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE...................................................................................................421 F-1 Bit pattern 20-(l) Swing oil pressure switch does not light up..................................................................423 F-2 Bit pattern 2042) Travel oil pressure switch does not light up..................................................................424 F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up.............................................................425 F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up.............................................................426 F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up.................................................................427 F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up................................................................428 F-7 Bit pattern 21-(l) Bucket CURL oil pressure switch does not light up............................................................429 F-8 Bit pattern 2142) Bucket DUMP oil pressure switch does not light up.............................................................430 F-9 Bit pattern 2%(3) Swing lock switch does not light up...........................................................................431 F-11 Bit pattern 22-(6) L.H. knob switch does not light up..........................................................................432 TROUBLESHOOTING OF HYDRAULIC, MONITOR SYSTEM (M MODE).......................................................................................468 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................470 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE...................................................................................................472 M-1 [E101] Abnormality in error data is displayed [E101] Error in clock data is displayed...........................................475 M-2 [E103] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed...................476 M-3 [E104] Air cleaner clogging detected is displayed...............................................................................477 M-4 [E106] Drop in engine oil Hi pressure detected is displayed.....................................................................477 M-5 [E108] Engine water temperature 105°C detected is displayed.....................................................................478 M-6 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds........................................479 M-7 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out....................................481 M-8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine (model)..................481 M-9 When starting switch is turned ON (engine stopped), basic check items flashes...................................................482 M-10 Preheating is not used but (preheating monitor) lights up......................................................................485 M-11 When starting switch is turned ON and engine is started, basic check items flash...............................................486 M-12 When starting switch is turned ON (engine speed), caution items, emergency items flash.........................................488 M-13 When starting switch is turned ON and engine is started, caution items, emergency items flash..................................490 M-14 When staring switch is turned ON (engine stopped), buzzer doesn't sound for 1 second Caution item flashes but doesn't sound....493 M-15 No abnormality is displayed on monitor but buzzer sounds.......................................................................493 M-16 Night light on monitor panel does not light up (liquid crystal display is normal)..............................................494 M-17 Coolant temperature gauge does not rise........................................................................................495 M-18 Coolant temperature gauge does not give any display (none of gauge lamps light up during operation)............................495 M-19 Fuel level gauge always displays FULL..........................................................................................496 M-20 Fuel level gauge does not give display.........................................................................................496 M-21 Swing lock switch is turned ON (LOCK) but (swing lock monitor) does not light up...............................................497 M-22 Swing prolix switch is turned ON (LOCK) but (swing lock monitor) does not flash................................................497 M-23 Service meter does not advance while engine is running.........................................................................498 M-24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed............................498 M-25 Defective fuel level sensor system.............................................................................................499 M-26 Defective coolant temperature sensor system....................................................................................500 M-27 Defective engine oil level sensor system.......................................................................................501 M-28 Defective coolant level sensor system..........................................................................................502 M-29 Defective hydraulic oil level sensor system....................................................................................503 M-30 Wiper does not work or switch is not being used but wiper is actuated..........................................................504 30 DISASSEMBLY AND ASSEMBLY.........................................................................................................................508 METHOD OF USING MANUAL .........................................................................................................................510 PRECAUTIONS WHEN CARRYING OUT OPERATION ........................................................................................................512 SPECIAL TOOL LIST ..............................................................................................................................514 SKETCHES OF SPECIAL TOOLS ......................................................................................................................522 STARTING MOTOR .................................................................................................................................530 ALTERNATOR .....................................................................................................................................530 ENGINE OIL COOLER ..............................................................................................................................530 FUEL INJECTION PUMP ............................................................................................................................530 WATER PUMP .....................................................................................................................................531 NOZZLE HOLDER ..................................................................................................................................531 TURBOCHARGER ...................................................................................................................................531 THERMOSTAT .....................................................................................................................................531 ENGINE FRONT SEAL ..............................................................................................................................532 CYLINDER HEAD ..................................................................................................................................532 GOVERNOR MOTOR..................................................................................................................................533 REMOVAL OF GOVERNOR MOTOR ..................................................................................................................533 INSTALLATION OF GOVERNOR MOTOR .............................................................................................................533 HYDRAULIC COOLER................................................................................................................................534 REMOVAL OF HYDRAULIC COOLER ................................................................................................................534 INSTALLATION OF HYDRAULIC COOLER ...........................................................................................................534 RADIATOR, HYDRAULIC COOLER......................................................................................................................535 REMOVAL OF RADIATOR, HYDRAULIC COOLER ......................................................................................................535 INSTALLATION OF RADIATOR, HYDRAULIC COOLER ................................................................................................536 ENGINE, MAIN PUMP...............................................................................................................................537 REMOVAL OF ENGINE, MAIN PUMP ...............................................................................................................537 INSTALLATION OF ENGINE, MAIN PUMP ..........................................................................................................540 DAMPER..........................................................................................................................................541 REMOVAL OF DAMPER ..........................................................................................................................541 INSTALLATION OF DAMPER .....................................................................................................................541 FUEL TANK.......................................................................................................................................542 REMOVAL OF FUEL TANK........................................................................................................................542 INSTALLATION OF FUEL TANK ..................................................................................................................542 CENTER SWIVEL JOINT.............................................................................................................................543 REMOVAL OF CENTER SWIVEL JOINT .............................................................................................................543 INSTALLATION OF CENTER JOINT ...............................................................................................................543 DISASSEMBLY OF CENTER SWIVEL JOINT .........................................................................................................544 ASSEMBLY OF CENTER SWIVEL JOINT ............................................................................................................544 FINAL DRIVE - PC3OOLC...........................................................................................................................545 REMOVAL OF FINAL DRIVE - PC3OOLC ...........................................................................................................545 INSTALLATION OF FINAL DRIVE ................................................................................................................545 DISASSEMBLY OF FINAL DRIVE .................................................................................................................546 ASSEMBLY OF FINAL DRIVE ....................................................................................................................550 FINAL DRIVE - PC300HD...........................................................................................................................557 REMOVAL OF FINAL DRIVE - PC300HD ...........................................................................................................557 INSTALLATION OF FINAL DRIVE ................................................................................................................557 DISASSEMBLY OF FINAL DRIVE .................................................................................................................558 ASSEMBLY OF FINAL DRIVE.....................................................................................................................562 TRAVEL MOTOR - PC3OOLC..........................................................................................................................569 DISASSEMBLY OF TRAVEL MOTOR - PC3OOLC ......................................................................................................569 ASSEMBLY OF TRAVEL MOTOR ...................................................................................................................573 TRAVEL MOTOR - PC300HD..........................................................................................................................582 DISASSEMBLY OF TRAVEL MOTOR - PC300HD ......................................................................................................582 ASSEMBLY OF TRAVEL MOTOR ...................................................................................................................586 SPROCKET........................................................................................................................................596 REMOVAL OF SPROCKET ........................................................................................................................596 INSTALLATION OF SPROCKET ...................................................................................................................596 SWING MOTOR.....................................................................................................................................597 REMOVAL OF SWING MOTOR .....................................................................................................................597 INSTALLATION OF SWING MOTOR ................................................................................................................597 DISASSEMBLY OF SWING MOTOR .................................................................................................................598 ASSEMBLY OF SWING MOTOR ....................................................................................................................600 SWING MACHINERY.................................................................................................................................607 REMOVAL OF SWING MACHINERY .................................................................................................................607 INSTALLATION OF SWING MACHINERY ............................................................................................................607 DISASSEMBLY OF SWING MACHINERY .............................................................................................................607 ASSEMBLY OF SWING MACHINERY.................................................................................................................611 REVOLVING FRAME.................................................................................................................................616 REMOVAL OF REVOLVING FRAME .................................................................................................................616 INSTALLATION OF REVOLVING FRAME ............................................................................................................617 SWING CIRCLE....................................................................................................................................618 REMOVAL OF SWING CIRCLE ....................................................................................................................618 INSTALLATION OF SWING CIRCLE ...............................................................................................................618 IDLER, RECOIL SPRING............................................................................................................................619 REMOVAL OF IDLER, RECOIL SPRING ............................................................................................................619 INSTALLATION OF IDLER, RECOIL SPRING ......................................................................................................619 IDLER - PC3OOLC.................................................................................................................................620 DISASSEMBLY OF IDLER - PC3OOLC .............................................................................................................620 ASSEMBLY OF IDLER ..........................................................................................................................621 IDLER - PC300HD.................................................................................................................................623 DISASSEMBLY OF IDLER - PC300HD .............................................................................................................623 ASSEMBLY OF IDLER ..........................................................................................................................624 RECOIL SPRING...................................................................................................................................626 DISASSEMBLY OF RECOIL SPRING ...............................................................................................................626 ASSEMBLY OF RECOIL SPRING ..................................................................................................................627 TRACK ROLLER....................................................................................................................................628 REMOVAL OF TRACK ROLLER ....................................................................................................................628 INSTALLATION OF TRACK ROLLER ...............................................................................................................628 DISASSEMBLY OF TRACK ROLLER ................................................................................................................629 ASSEMBLY OF TRACK ROLLER ...................................................................................................................630 CARRIER ROLLER..................................................................................................................................632 REMOVAL OF CARRIER ROLLER ..................................................................................................................632 INSTALLATION OF CARRIER ROLLER .............................................................................................................632 DISASSEMBLY OF CARRIER ROLLER ..............................................................................................................633 ASSEMBLY OF CARRIER ROLLER .................................................................................................................634 TRACK SHOE......................................................................................................................................637 REMOVAL OF TRACK SHOE ......................................................................................................................637 INSTALLATION OF TRACK SHOE .................................................................................................................637 HYDRAULIC TANK..................................................................................................................................638 REMOVAL OF HYDRAULIC TANK ..................................................................................................................638 INSTALLATION OF HYDRAULIC TANK .............................................................................................................639 CONTROL PUMP....................................................................................................................................640 REMOVAL OF CONTROL PUMP ....................................................................................................................640 INSTALLATION OF CONTROL PUMP ...............................................................................................................640 MAIN PUMP.......................................................................................................................................641 REMOVAL OF MAIN PUMP .......................................................................................................................641 INSTALLATION OF MAIN PUMP ..................................................................................................................642 DISASSEMBLY OF MAIN PUMP ...................................................................................................................643 ASSEMBLY OF MAIN PUMP ......................................................................................................................649 CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, ROCKER CAM AND CRADLE, VALVE PLATE AND END CAP ...................................658 MAIN PUMP INPUT SHAFT OIL SEAL..................................................................................................................660 REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL ..................................................................................................660 INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL ............................................................................................660 CONTROL VALVE...................................................................................................................................661 REMOVAL OF CONTROL VALVE ...................................................................................................................661 INSTALLATION OF CONTROL VALVE ..............................................................................................................663 DISASSEMBLY OF CONTROL VALVE ...............................................................................................................664 ASSEMBLY OF CONTROL VALVE ..................................................................................................................667 PUMP MERGE/DIVIDER VALVE........................................................................................................................671 DISASSEMBLY OF PUMP MERGE/DIVIDER VALVE ....................................................................................................671 ASSEMBLY OF PUMP MERGE/DIVIDER VALVE ......................................................................................................671 PRESSURE COMPENSATION VALVE.....................................................................................................................672 DISASSEMBLY OF PRESSURE COMPENSATION VALVE .................................................................................................672 ASSEMBLY OF PRESSURE COMPENSATION VALVE ...................................................................................................672 SERVO VALVE FOR FRONT PUMP......................................................................................................................673 REMOVAL OF SERVO VALVE FOR FRONT PUMP ......................................................................................................673 INSTALLATION OF SERVO VALVE FOR FRONT PUMP ................................................................................................673 SERVO VALVE FOR REAR PUMP.......................................................................................................................674 REMOVAL OF SERVO VALVE FOR REAR PUMP .......................................................................................................674 INSTALLATION OF SERVO VALVE FOR REAR PUMP .................................................................................................674 LS-EPC SOLENOID VALVE...........................................................................................................................675 REMOVAL OF LS-EPC SOLENOID VALVE ...........................................................................................................675 INSTALLATION OF LS-EPC SOLENOID VALVE .....................................................................................................675 SOLENOID VALVE..................................................................................................................................676 REMOVAL OF SOLENOID VALVE ..................................................................................................................676 INSTALLATION OF SOLENOID VALVE .............................................................................................................676 WORK EQUIPMENT PPC VALVE........................................................................................................................677 REMOVAL OF WORK EQUIPMENT PPC VALVE ........................................................................................................677 INSTALLATION OF WORK EQUIPMENT PPC VALVE ..................................................................................................677 WORK EQUIPMENT PPC VALVE........................................................................................................................678 DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ....................................................................................................678 ASSEMBLY OF WORK EQUIPMENT PPC VALVE ......................................................................................................678 TRAVEL PPC VALVE................................................................................................................................679 REMOVAL OF TRAVEL PPC VALVE ................................................................................................................679 INSTALLATION OF TRAVEL PPC VALVE ...........................................................................................................679 DISASSEMBLY OF TRAVEL PPC VALVE ............................................................................................................680 ASSEMBLY OF TRAVEL PPC VALVE ...............................................................................................................681 REMOVAL OF PPC SHUTTLE VALVE ...............................................................................................................682 INSTALLATION OF PPC SHUTTLE VALVE ..........................................................................................................683 DISASSEMBLY OF PPC SHUTTLE VALVE ...........................................................................................................684 ASSEMBLY OF PPC SHUTTLE VALVE ..............................................................................................................685 BOOM LOCK VALVE.................................................................................................................................686 REMOVAL OF BOOM LOCK VALVE..................................................................................................................686 INSTALLATION OF BOOM LOCK VALVE ............................................................................................................686 DISASSEMBLY OF BOOM LOCK VALVE .............................................................................................................686 ASSEMBLY OF BOOM LOCK VALVE ................................................................................................................686 BOOM CYLINDER...................................................................................................................................687 REMOVAL OF BOOM CYLINDER ...................................................................................................................687 INSTALLATION OF BOOM CYLINDER ..............................................................................................................688 ARM CYLINDER....................................................................................................................................689 REMOVAL OF ARM CYLINDER ....................................................................................................................689 INSTALLATION OF ARM CYLINDER ...............................................................................................................690 BUCKET CYLINDER.................................................................................................................................691 REMOVAL OF BUCKET CYLINDER .................................................................................................................691 INSTALLATION OF BOOM CYLINDER ..............................................................................................................692 HYDRAULIC CYLINDER..............................................................................................................................693 DISASSEMBLY OF HYDRAULIC CYLINDER ..........................................................................................................693 ASSEMBLY OF HYDRAULIC CYLINDER..............................................................................................................695 WORK EQUIPMENT..................................................................................................................................697 REMOVAL OF WORK EQUIPMENT ..................................................................................................................697 INSTALLATION OF WORK EQUIPMENT .............................................................................................................698 BUCKET..........................................................................................................................................699 REMOVAL OF BUCKET ..........................................................................................................................699 INSTALLATION OF BUCKET .....................................................................................................................700 ARM.............................................................................................................................................701 REMOVAL OF ARM .............................................................................................................................701 INSTALLATION OF ARM ........................................................................................................................702 BUCKET, ARM.....................................................................................................................................703 REMOVAL OF BUCKET, ARM .....................................................................................................................703 INSTALLATION OF BUCKET, ARM ................................................................................................................704 BOOM............................................................................................................................................705 REMOVAL OF BOOM ............................................................................................................................705 INSTALLATION OF BOOM .......................................................................................................................706 OPERATORS CAB...................................................................................................................................707 REMOVAL OF OPERATORS CAB....................................................................................................................707 INSTALLATION OF OPERATORS CAB ..............................................................................................................708 COUNTERWEIGHT...................................................................................................................................709 REMOVAL OF COUNTERWEIGHT ...................................................................................................................709 INSTALLATION OF COUNTERWEIGHT ..............................................................................................................709 AIR CONDITIONER COMPRESSOR......................................................................................................................710 REMOVAL OF AIR CONDITIONER COMPRESSOR ......................................................................................................710 INSTALLATION OF AIR CONDITIONER COMPRESSOR ................................................................................................710 CONDENSER.......................................................................................................................................711 REMOVAL OF CONDENSER .......................................................................................................................711 INSTALLATION OF CONDENSER ..................................................................................................................711 AIR CONDITIONER UNIT............................................................................................................................712 REMOVAL OF AIR CONDITIONER UNIT ............................................................................................................712 INSTALLATION OF AIR CONDITIONER UNIT ......................................................................................................713 GOVERNOR, PUMP CONTROLLER.......................................................................................................................714 REMOVAL OF GOVERNOR, PUMP CONTROLLER .......................................................................................................714 INSTALLATION OF GOVERNOR, PUMP CONTROLLER .................................................................................................714 MONITOR PANEL...................................................................................................................................715 REMOVAL OF MONITOR PANEL....................................................................................................................715 INSTALLATION OF MONITOR PANEL ..............................................................................................................715 CONTROL STAND CASE..............................................................................................................................716 REMOVAL OF CONTROL STAND CASE ..............................................................................................................716 INSTALLATION OF CONTROL STAND CASE ........................................................................................................717 40 MAINTENANCE STANDARD.............................................................................................................................718 ENGINE MOUNT....................................................................................................................................719 SWING MACHINERY ................................................................................................................................720 SWING CIRCLE ...................................................................................................................................722 FINAL DRIVE (PC300LC-6).........................................................................................................................723 FINAL DRIVE (PC300HD-6).........................................................................................................................725 TRACK FRAME - RECOIL SPRING (PC300LC-6).........................................................................................................727 TRACK FRAME - RECOIL SPRING (PC300HD-6).........................................................................................................728 IDLER (PC300LC-6)...............................................................................................................................729 IDLER (PC300HD-6)...............................................................................................................................731 CARRIER ROLLER .................................................................................................................................732 TRACK ROLLER....................................................................................................................................733 TRACK CHAIN ASSM. (PC300LC-6)...................................................................................................................735 TRACK CHAIN ASSM. (PC300HD-6)...................................................................................................................736 HYDRAULIC PUMP .................................................................................................................................737 CONTROL PUMP AND RELIEF VALVE ..................................................................................................................738 CONTROL VALVE (10-SPOOL)........................................................................................................................739 SUCTION-SAFETY VALVE............................................................................................................................745 SWING MOTOR ....................................................................................................................................746 TRAVEL MOTOR (PC300LC-6)........................................................................................................................747 TRAVEL MOTOR (PC300HD-6)........................................................................................................................748 WORK EQUIPMENT - SWING PPC VALVE ...............................................................................................................749 TRAVEL PPC VALVE ...............................................................................................................................750 SERVICE PPC VALVE ..............................................................................................................................751 PPC SHUTTLE VALVE - TRAVEL JUNCTION VALVE ......................................................................................................752 EPC - SOLENOID VALVE ...........................................................................................................................753 CENTER SWIVEL JOINT.............................................................................................................................754 BOOM HOLDING VALVE..............................................................................................................................755 HYDRAULIC CYLINDER .............................................................................................................................756 WORK EQUIPMENT .................................................................................................................................757
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