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KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SN:A83001 and up) – PDF DOWNLOAD
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- KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:A83001 and up
- PUBLICATION NUMBER:CEBM002901
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Description
KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SN:A83001 and up)
KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SN:A83001 AND UP) – PDF DOWNLOAD:
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KOMATSU PC300LC-6 PC300HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL(SN:A83001 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, ADJUSTING AND TROUBLESHOOTING
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:A83001 and up)
MAIN MENU................................................................................................................................... 0 COVER....................................................................................................................................... 1 CONTENTS.................................................................................................................................... 2 00 FORWARD.................................................................................................................................. 9 SAFETY.................................................................................................................................. 10 GENERAL................................................................................................................................. 12 HOW TO READ THE SHOP MANUAL............................................................................................................. 13 HOISTING INSTRUCTIONS................................................................................................................... 14 COATING MATERIALS....................................................................................................................... 15 STANDARD TIGHTENING TORQUE.............................................................................................................. 17 ELECTRIC WIRE CODE...................................................................................................................... 21 CONVERSION TABLES....................................................................................................................... 22 METHOD OF USING THE CONVERSION TABLE.................................................................................................... 22 01 GENERAL.................................................................................................................................. 28 SPECIFICATION DRAWINGS.................................................................................................................. 29 SPECIFICATIONS.......................................................................................................................... 33 WEIGHT TABLE............................................................................................................................ 35 FUEL COLLANT AND LUBRICANTS............................................................................................................. 37 10 STRUCTURE AND FUNCTION................................................................................................................... 44 PARTS RELATED TO ENGINE................................................................................................................. 45 RADIATOR, OIL COOLER.................................................................................................................... 48 POWER TRAIN............................................................................................................................. 51 FINAL DRIVE............................................................................................................................. 52 SWING CIRCLE............................................................................................................................ 57 SWING MACHINERY......................................................................................................................... 58 TRACK FRAME, RECOIL SPRING.............................................................................................................. 61 TRACK SHOE.............................................................................................................................. 64 HYDRAULIC PIPING DRAWING................................................................................................................ 65 HYDRAULIC CIRCUIT DIAGRAM............................................................................................................... 67 HYDRAULIC TANK AND FILTER............................................................................................................... 68 HYDRAULIC PUMP.......................................................................................................................... 69 CONTROL VALVE........................................................................................................................... 89 SELF REDUCING PRESURE VALVE............................................................................................................. 97 SUCTION SAFETY VALVE....................................................................................................................102 CLSS....................................................................................................................................104 SWING MOTOR.............................................................................................................................147 CENTER SWIVEL JOINT.....................................................................................................................151 TRAVEL MOTOR............................................................................................................................152 VALVE CONTROL...........................................................................................................................170 WORK EQUIPMENT PPC VALVE................................................................................................................171 TRAVEL PPC VALVE........................................................................................................................175 PPC SAFETY LOCK VALVE...................................................................................................................181 PPC ACCUMULATOR.........................................................................................................................182 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE................................................................................................183 LS-EPC VALVE............................................................................................................................190 SOLENOID VALVE..........................................................................................................................193 BOOM HOLDING VALVE......................................................................................................................195 WORK EQUIPMENT..........................................................................................................................198 AIR CONDITIONER.........................................................................................................................199 ELECTRICAL WIRING SCHEMATIC.............................................................................................................200 ELECTRICAL WIRING DIAGRAM...............................................................................................................201 ENGINE CONTROL..........................................................................................................................204 ELECTRONIC CONTROL SYSTEM...............................................................................................................211 MACHINE MONITOR CONTROL.................................................................................................................234 20 TESTING AND ADJUSTING....................................................................................................................244 TESTING AND ADJUSTING...................................................................................................................244 STANDARD VALUE TABLE FOR ENGINE.....................................................................................................245 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS......................................................................................246 STANDARD VALUE TABLE FOR ELECTRICAL PARTS...........................................................................................251 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING....................................................................................257 MEASURING ENGINE SPEED..............................................................................................................258 INTAKE MAIFOLD PRESSURE.............................................................................................................259 INTAKE AIR RESTRICTION..............................................................................................................259 LUBRICATING OIL PRESSURE............................................................................................................259 FUEL [FILTER] INLET RESTRICTION.....................................................................................................259 BLOW BY PRESSURE....................................................................................................................260 ENGINE BACK PRESSURE................................................................................................................260 COOLANT TEMPERATURE.................................................................................................................260 VALVE CLEARANCE.....................................................................................................................260 MEASURING EXHAUST COLOR.............................................................................................................261 GOVERNOR MOTOR LEVER STROKE.........................................................................................................262 WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................................................................................263 TVC VALVE OUTPUT PRESSURE...........................................................................................................266 LS VALVE OUTPUT PRESSURE............................................................................................................268 LS DIFFERENTIAL PRESURE.............................................................................................................268 CONTROL CIRCUIT OIL PRESSURE........................................................................................................271 SOLENOID VALVE OUTPUT PRESSURE......................................................................................................272 PPC VALVE OUTPUT PRESSURE AND PPC SHUTTLE VALVE.....................................................................................275 WORK EQUIPMENT, SWING PPC VALVE.....................................................................................................277 TRAVEL DEVIATION....................................................................................................................278 HYDRAULIC DRIFT OF WORK EQUIPMENT...................................................................................................279 MEASURING OIL LEAKAGE...............................................................................................................281 RELEASING REMAINING PRESSURE........................................................................................................284 SWING CIRCLE BEARING................................................................................................................285 WEAR OF SPROCKET....................................................................................................................286 TRACK SHOE TENSION..................................................................................................................287 BLEEDING AIR........................................................................................................................288 TROUBLESHOOTING.....................................................................................................................291 TESTING AND ADJUSTMENT..................................................................................................................256 TOOLS FOR TESTIN, ADJUSTING AND TROUBLESHOOTING.....................................................................................257 MEASURING ENGINE SPEED..............................................................................................................258 INTAKE MANIFOLD PRESSURE............................................................................................................259 INTAKE AIR RESTRICTION..............................................................................................................259 LUBRICATING OIL PRESSURE............................................................................................................259 FUEL [FILTER] INLET RESTRICTION.....................................................................................................259 BLOW BY PRESSURE....................................................................................................................260 ENGINE BACK PRESSURE................................................................................................................260 COOLANT TEMPERATURE.................................................................................................................260 VALVE CLEARANCE.....................................................................................................................260 MEASURING EXHAUST COLOR.............................................................................................................261 GOVERNOR MOTOR LEVER STROKE.........................................................................................................262 WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................................................................................263 TVC VALVE OUTPUT PRESSURE...........................................................................................................266 LS VALVE OUTPUT PRESSURE AN DLS DIFFERENTIAL PRESSURE...............................................................................268 CONTROL CIRCUIT OIL PRESSURE........................................................................................................271 SOLENOID VALVE OUPUT PRESSURE.......................................................................................................272 PPC VALVE OUTPUT PRESSURE AND PPC SHUTTLE VALVE.....................................................................................275 WORK EQUIPMENT, SWING PPC VALVE.....................................................................................................277 TRAVEL DEVIATION....................................................................................................................278 LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.................................................................................279 MEASURING OIL LEAKAGE...............................................................................................................281 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...................................................................................284 TESTING CLEARANCE OF SWING CIRCLE BEARING...........................................................................................285 WEAR OF SPROCKET....................................................................................................................286 TRACK SHOE TENSION..................................................................................................................287 BLEEDING AIR........................................................................................................................288 TROUBLESHOOTING.........................................................................................................................291 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................292 SEQUENCE OF EVENTS IN TROUBLESHOOTING...............................................................................................293 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....................................................................................294 CHECKS BEFORE TROUBLSHOOTING........................................................................................................303 CONNECTOR TYPES AND MOUNTING LOCATIONS..............................................................................................304 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..........................................................................................307 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM..............................................................................317 DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL.............................................................................318 METHOD OF USING JUDGEMENT TABLE.....................................................................................................326 METHOD OF USING TROUBLSHOOTING CHARTS...............................................................................................328 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE............................................................................331 SERVICE CODE TABLE..................................................................................................................335 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM N MODE..............................................................................336 N-1 [E218] COMMUNICATION ABNORMALITY...............................................................................................337 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER GOVEROR CONTROL SYSTEM E MODE..............................................................339 POINTS TO REMEMBER..................................................................................................................340 ACTIONS TAKEN.......................................................................................................................341 JUDGEMENT TABLE.....................................................................................................................343 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM........................................................................................344 E-1 ABNORMAILITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE, CONTROLLER LED IS OFF..................................................345 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED..............................................................346 E-3 [E317] ABNORMALITY, DISCONNECTION IN MOTOR DRIVE SYSTEM IS DISPLAYED..........................................................347 E-4 [E318] ABNORMALITY, SHORT CIRCUIT IN MOTOR DRIVE SYSTEM IS DISPLAYED..........................................................348 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED..............................................................349 E-6 [E315] ABNORMALITY, SHORT CIRCUIT IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED.................................................350 E-7 [E316] ABNORMALITY, STEP OUT IN MOTOR DISPLAYED...............................................................................351 E-8 ENGINE DOES NOT START..........................................................................................................352 E-9 ENGINE SPEED IS IRREGULAR......................................................................................................354 E-10 LACK OF OUTPUT, ENGINE HIGH IDLE SPEED IS TO LOW..............................................................................356 E-11 ENGINE DOES NOT STOP..........................................................................................................357 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM, ENGINE DOES NOT STOP.............................................................358 TROUBLESHOOTING OF ENGINE SYSTEM S MODE.................................................................................................360 METHOD OF USING CHARTS..............................................................................................................361 S-1 STARTING PERFORMANCE IS POOR, STARTING ALWAYS TAKES TIME.......................................................................365 S-2 ENGINE DOES NOT START..........................................................................................................366 S-3 ENGINE DOES NOT PICK UP SMOOTHLY, FOLLOW UP IS POOR............................................................................369 S-4 ENGINE STOPS DURING OPERATION..................................................................................................370 S-5 ENGINE DOES NOT ROTATE SMOOTHLY, HUNTING.......................................................................................371 S-6 ENGINE LACKS OUTPUT, NO POWER..................................................................................................372 S-7 ENGINE SMOKE IS BLACK, INCOPLETE COMBUSTION....................................................................................373 S-8 OIL CONSUMPTIONIS EXCESSIVE, OR EXHAUST SMOKE IS BLUE..........................................................................374 S-9 OIL BECOMES CONTAMINATED QUICKLY...............................................................................................374 S-1O FUEL CONSUMPTION IS EXCESSIVE.................................................................................................374 S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN.........................................................374 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP, DROP IN OIL PRESSURE.....................................................................374 S-13 OIL LEVEL RISES; COOLANT, FUEL IN OIL.........................................................................................375 S-14 COOLANT 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 POINTS TO REMEMBER..................................................................................................................380 ACTIONS TAKEN BY CONTROLLER.........................................................................................................381 JUDGEMENT TABLE.....................................................................................................................385 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE...............................................................................................386 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM, CONTROLLER LED IS OFF...........................................................388 C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED...........................................................389 C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID IS DISPLAYED..................................................................390 C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED............................................................391 C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED............................................................392 C-6 [E207] SHORT CIRCUIT IN LS SELECT SOLENOID SYSTEM IS DISPLAYED................................................................393 C-7 [E208] DISCONNECTION IN ACTIVE MODE, BOOM, SOLENOID SYSTEM IS DISPLAYED.......................................................395 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED..............................................................396 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED..............................................................397 C-10 [E204] SHORT CIRCUIT IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED......................................................398 C-11 [E214] DISCONNECTION IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED......................................................399 C-12 [E206] SHORT CIRCUIT IN TRAVEL SPED SOLENOIDSYSTEM IS DISPLAYED..............................................................400 C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED...................................................401 C-14 [E217] SHORT CIRCUIT IN ACTIVE MODE, SWING, SOLENOID SYSTEM IS DISPLAED......................................................402 C-15 [E235] DISCONNECTION IN ACTIVE MODE, SWING, SOLENOID SYSTEM IS DISPLAYED.....................................................403 C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED..............................................................................404 C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYTEM IS DISPLAYED...................................................................406 C-18 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED..................................................................407 C-19 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.........................................................408 C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED..........................................................409 C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED.......................................................410 C-22 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED................................................................411 C-23 ABNORMALITY IN MACHINE PUSH UP SOLENOID SYSTEM , NO SERVICE CODE DISPLAYED....................................................412 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER, INPUT SIGNAL SYSTEM F MODE................................................................414 ELECTRIC CIRCUIT DIAGRAM FOR F MODE.................................................................................................416 F-1 BIT PATTERN 20-[1] SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP................................................................417 F-2 BIT PATTERN 20-[2] TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................418 F-3 BIT PATTERN 20-[3] BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP...........................................................419 F-4 BIT PATTERN 20-[4] BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP...........................................................420 F-5 BIT PATTERN 20-[5] ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................421 F-6 BIT PATTERN 20-[6] ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................422 F-7 BIT PATTERN 21-[1] BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................423 F-8 BIT PATTERN 21-[2] BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................424 F-9 BIT PATTERN 21-[3] SWING LOCK SWITCH DOES NOT LIGHT UP........................................................................425 F-10 BIT PATTERN 22-[5] MODE CONNECTION DOES NOT LIGHT UP.........................................................................426 F-11 BIT PATTERN 22-[6] LEFT KNOB SWITCH DOES NOT LIGHT UP........................................................................427 TROUBLESHOOTING OF MACHINE MECHANICAL SYSTEM H MODE.....................................................................................428 PUMP MERGE DIVIDER LOGIC............................................................................................................429 SOLENOID ACTUATION TABLE............................................................................................................429 TABLE OF FAILURE MODES AND CAUSES...................................................................................................430 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER.............................................................432 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS......................................................................433 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVEMENT......................................................................................433 H-4 ABNORMAL NOISE GENERATED AROUND PUMP...........................................................................................434 H-5 AUTO DECELERATION DOES NOT WORK, WHEN PPC SHUTTLE VALVE IS CAUSE...............................................................434 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...............................................................................434 H-7 BOOM IS SLOW OR LACKS POWER....................................................................................................435 H-8 ARM IS SLOW OR LACKS POWER.....................................................................................................436 H-9 BUCKET IS SLOW OR LACKS POWER..................................................................................................437 H-10 WORK EQUIPMENT; BOOM, ARM, BUCKET, DOES NOT MOVE, BUT TRAVEL AND SWING ARE NORMAL.............................................438 H-11 EXCESSIVE HYDRAULIC DRIFT, BOOM, ARM, BUCKET..................................................................................438 H-12 EXCESSIVE TIME LAG, ENGINE AT LOW IDLING......................................................................................439 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED.........................................................................439 H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEE.........................................................440 H-15 MALFUNCTION OF MACHINE PUSH UP FUNCTION.......................................................................................440 H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW...............................................................440 H-17 IN SWING PLUS BOOM RAISE, BOOM RAISE IS SLOW...................................................................................441 H-18 IN SWING PLUS ARM, ARM IS SLOW................................................................................................441 H-19 IN SWING PLUS TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY..........................................................................441 H-20 TRAVEL DEVIATION..............................................................................................................442 H-21 TRAVEL SPEED IS LOW...........................................................................................................444 H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER..................................................................................445 H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED................................................................446 H-24 TRAVEL DOES NOT MOVE, ONE SIDE ONLY...........................................................................................446 H-25 DOES NOT SWING................................................................................................................447 H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW.............................................................................448 H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING.........................................................................................449 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING, ONE DIRECTION ONLY.......................................................................450 H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..................................................................................450 H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING............................................................................................451 H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED..............................................................................451 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM M MODE........................................................................................452 ACTIONS TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE......................................................452 ELECTRIC CIRCUIT DIAGRAM FOR M MODE.................................................................................................455 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED.................................................................................456 [E101] ERROR IN CLOCK DATA IS DISPLAYED...................................................................................456 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR 24V WIRING HARNESS CONTACKT WITH BUZZERNESS IS DISPLAYED.............................457 M3 [E104] AIR CLEANER RESTRICTION DETECTED IS DISPLAYED...........................................................................458 M4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED....................................................................458 M5 [E108] ENGINE COOLANT TEMPERATURE 1O5 DEGREES CELS DETECTED IS DISPLAYEDIUS....................................................458 M-6 WHEN START SWITCH IS TURNED ON, NO LAMPS ON MONITOR PANEL LIGHT UP FOR THREE SECONDS...........................................459 M-7 WHEN START SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY ILLUMINATED AND DO NOT GO OUT.....................................461 M-8 WHEN START SWITCH IS TURNED ON, ITEMS ILLUMINATED ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE...........................461 M-9 WHEN START SWITCH IS TURNED ON, ENGINE STOPPED, BASIC CHECK ITEMS FLASH........................................................462 M-10 PREHEATING IS NOT USED, BUT MONITOR PANEL LIGHTS UP...........................................................................465 M-11 WHEN START SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH.................................................466 M-12 WHEN START SWITCH IS TURNED ON, ENG. SPEED, CAUTION ITEMS, EMERGENCY ITEMS FLASH. BATTERY ENG. OIL PRESSURE LAMPS DO NOT ....468 M-13 WHEN START SWITCH IS TURNED ON AND ENG. IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH, WHEN THERE IS NO ABNORMALTY IN E....470 M-14 WHEN START SWITCH IS TURNED ON, ENG. STOPPED, BUZZER DOES NOT SOUND FOR ONE SECOND, CAUTION ITEMS FLASH BUT DO NOT SOUND......473 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR PANEL BUT BUZZER SOUNDS................................................................474 M-16 NIGHT LIGHT ON MONITOR PANEL DOES NOT LIGHT UP, LIQUID CRYSTAL DISPLAY IS NORMAL..............................................475 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE.......................................................................................476 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY, NO GUAGE LAMPS LIGH UP DURING OPERATION..................................477 M-19 FUEL LEVEL GUAGE ALWAYS DISPLAYS FULL.........................................................................................478 M-20 FUEL LEVEL GUAGE DOES NOT GIVE DISPLAY........................................................................................479 M-21 SWING LOCK SWITCH IS TURNED ON, BUT MONITOR PANEL DOES NOT LIGHT .............................................................480 M-22 SWING PROLIX SWITCH IS TURNED ON, BUT MONITOR PANEL DOES NOT FLASH............................................................481 M-23 SERVICE METER DOES NOT ADVANCE WHIL ENGINE IS RUNNING.........................................................................482 M-24 WHEN START SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED..............................482 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM............................................................................................483 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM...................................................................................484 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM......................................................................................485 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.........................................................................................486 M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM...................................................................................487 M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED [INCLUDE E112, E113]....................................488 M-31 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED [INCLUDEE114]....................................492 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................494 METHOD OF USING MANUAL..................................................................................................................495 PRECAUTIONS.............................................................................................................................497 SPECIAL TOOL LIST.......................................................................................................................500 SKETCHES OF SPECIAL TOOLS...............................................................................................................507 ENGINE COMPONENTS.......................................................................................................................515 GOVERNOR MOTOR..........................................................................................................................518 OIL COOLER..............................................................................................................................519 RADIATOR, OIL COOLER....................................................................................................................520 ENGINE, MAIN PUMP.......................................................................................................................522 DAMPER..................................................................................................................................526 FUEL TANK...............................................................................................................................527 CENTER SWIVEL JOINT.....................................................................................................................528 FINAL DRIVE - PC300LC-6.................................................................................................................530 FINAL DRIVE - PC300HD-6.................................................................................................................541 TRAVEL MOTOR - PC300LC-6................................................................................................................552 TRAVEL MOTOR - PC300HD-6................................................................................................................565 SPROCKET................................................................................................................................578 SWING MOTOR.............................................................................................................................579 SWING MACHINERY.........................................................................................................................589 REVOLVING FRAME.........................................................................................................................598 SWING CIRCLE............................................................................................................................600 IDLER AND RECOIL SPRING- PC300LC-6......................................................................................................601 IDLER AND RECOIL SPRING - PC300HD-6.....................................................................................................602 IDLER - PC300LC-6.......................................................................................................................603 IDLER - PC300HD-6.......................................................................................................................606 RECOIL SPRING...........................................................................................................................610 TRACK ROLLER............................................................................................................................612 CARRIER ROLLER..........................................................................................................................617 TRACK CHAIN.............................................................................................................................622 HYDRAULIC TANK..........................................................................................................................623 MAIN PUMP...............................................................................................................................625 MAIN PUMP OIL SEAL......................................................................................................................652 CONTROL VALVE...........................................................................................................................653 PUMP MERGE DIVIDER VALVE................................................................................................................667 PRESSURE COMPENSATION VALVE.............................................................................................................668 FRONT PUMP SERVO VALVE..................................................................................................................669 REAR PUMP SERVO VALVE...................................................................................................................670 LS-EPC SOLENOID VALVE...................................................................................................................671 SOLENOID VALVE..........................................................................................................................672 WORK EQUIPMENT PPC VALVE................................................................................................................673 TRAVEL PPC VALVE........................................................................................................................675 PPC SHUTTLE VALVE.......................................................................................................................677 BOOM LOCK VALVE.........................................................................................................................680 BOOM CYLINDER...........................................................................................................................682 ARM CYLINDER............................................................................................................................684 BUCKET CYLINDER.........................................................................................................................685 HYDRAULIC CYLINDER......................................................................................................................687 WORK EQUIPMENT..........................................................................................................................697 BUCKET..................................................................................................................................699 ARM.....................................................................................................................................701 BUCKET AND ARM..........................................................................................................................703 BOOM....................................................................................................................................705 OPERATORS CAB...........................................................................................................................707 COUNTERWEIGHT...........................................................................................................................709 COMPRESSOR..............................................................................................................................710 CONDENSER...............................................................................................................................711 RECEIVER TANK...........................................................................................................................712 AIR CONDITIONER UNIT....................................................................................................................713 GOVERNOR, PUMP CONTROLLER...............................................................................................................715 MONITOR PANEL...........................................................................................................................716 CONTROL STAND CASE......................................................................................................................717 40 MAINTENANCE STANDARD.....................................................................................................................719 ENGINE MOUNT............................................................................................................................720 SWING MACHINERY.........................................................................................................................724 SWING CIRCLE............................................................................................................................726 FINAL DRIVE - PC300LC-6.................................................................................................................728 FINAL DRIVE - PC300HC-6.................................................................................................................730 TRACK FRAME AND RECOIL SPRING...........................................................................................................732 IDLER - PC300LC-6.......................................................................................................................734 IDLER - PC300HD-6.......................................................................................................................736 CARRIER ROLLER..........................................................................................................................738 TRACK ROLLER - PC300LC-6................................................................................................................740 TRACK ROLLER - PC300HD-6................................................................................................................741 TRACK SHOE..............................................................................................................................742 HYDRAULIC PUMP..........................................................................................................................747 CONTROL VALVE...........................................................................................................................748 SELF REDUCING PRESSURE VALVE............................................................................................................755 SUCTION SAFETY VALVE....................................................................................................................756 SWING MOTOR.............................................................................................................................757 TRAVEL MOTOR - PC300LC-6................................................................................................................758 TRAVEL MOTOR - PC300HD-6................................................................................................................759 WORK EQUIPMENT - SWING PPC VALVE........................................................................................................760 TRAVEL PPC VALVE........................................................................................................................761 SERVICE PPC VALVE.......................................................................................................................762 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE................................................................................................763 LS-EPC VALVE............................................................................................................................764 SOLENOID VALVE..........................................................................................................................765 CENTER SWIVEL JOINT.....................................................................................................................766 BOOM HOLDING VALVE......................................................................................................................767 HYDRAULIC CYLINDER......................................................................................................................768 WORK EQUIPMENT..........................................................................................................................770 DIMENSIONS OF WORK EQUIPMENT............................................................................................................772 90 OTHER....................................................................................................................................776 FOLDOUT 1 HYDRAULIC SCHEMATIC...........................................................................................................776 FOLDOUT 2 ELECTRICAL WIRING SCHEMATIC (2/3).............................................................................................780 FOLDOUT 3 ELECTRICAL WIRING SHCEMATIC (3/3).............................................................................................784
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