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KOMATSU PC300LC-7L PC300HD-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A85001 & UP) – PDF DOWNLOAD
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- KOMATSU PC300LC-7L PC300HD-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:A85001 & UP
- PUBLICATION NUMBER:CEBM009104
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Description
KOMATSU PC300LC-7L PC300HD-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A85001 & UP)
KOMATSU PC300LC-7L PC300HD-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A85001 & UP) – PDF DOWNLOAD:
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KOMATSU PC300LC-7L PC300HD-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A85001 & 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-7L PC300HD-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A85001 & UP)
COVER............................................................................................................... 1 CONTENTS............................................................................................................ 2 FOREWORD............................................................................................................ 9 SAFETY.......................................................................................................... 9 SAFETY NOTICE............................................................................................... 9 IMPORTANT SAFETY NOTICE................................................................................. 9 GENERAL PRECAUTIONS..................................................................................... 9 PREPARATIONS FOR WORK................................................................................... 9 PRECAUTIONS DURING WORK................................................................................. 9 GENERAL......................................................................................................... 11 HOW TO READ THE SHOP MANUAL..................................................................................... 12 VOLUMES..................................................................................................... 12 DISTRIBUTION AND UPDATING................................................................................... 12 FILING METHOD............................................................................................... 12 REVISED EDITION MARK........................................................................................ 12 REVISIONS................................................................................................... 12 SYMBOLS..................................................................................................... 12 HOISTING INSTRUCTIONS........................................................................................... 13 HOISTING.................................................................................................... 13 WIRE ROPES.................................................................................................. 13 COATING MATERIALS............................................................................................... 14 STANDARD TIGHTENING TORQUE...................................................................................... 16 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS................................................................ 16 TIGHTENING TORQUE OF HOSE NUTS.............................................................................. 17 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS..................................................................... 17 TIGHTENING TORQUE FOR FLARED NUTS........................................................................... 17 ELECTRIC WIRE CODE.............................................................................................. 18 CLASSIFICATION BY THICKNESS................................................................................. 18 CLASSIFICATION BY COLOR AND CODE............................................................................ 18 CONVERSION TABLES............................................................................................... 19 METHOD OF USING THE CONVERSION TABLE........................................................................ 19 01 GENERAL.......................................................................................................... 25 SPECIFICATION DIMENSION DRAWINGS................................................................................ 26 DIMENSIONS.................................................................................................. 26 WORKING RANGES.............................................................................................. 26 DIMENSIONS.................................................................................................. 27 WORKING RANGES.............................................................................................. 27 SPECIFICATIONS.................................................................................................. 28 WEIGHT TABLE.................................................................................................... 30 FUEL, COOLANT, AND LUBRICANTS................................................................................... 32 PC300LC-7L.................................................................................................. 32 PC300HD-7L.................................................................................................. 33 10 STRUCTURE AND FUNCTION........................................................................................... 35 ENGINE RELATED PARTS............................................................................................ 37 RADIATOR • OIL COOLER • AFTERCOOLER............................................................................. 38 FINAL DRIVE..................................................................................................... 40 PC300LC-7L.................................................................................................. 40 PC300HD-7L.................................................................................................. 42 SPROCKET........................................................................................................ 43 REAL DIMENSION OF SPROCKET TOOTH SHAPE.......................................................................... 44 SWING MACHINERY................................................................................................. 46 SWING CIRCLE.................................................................................................... 48 TRACK FRAME • RECOIL SPRING..................................................................................... 50 PC300LC-7L.................................................................................................. 50 PC300HD-7L.................................................................................................. 52 IDLER........................................................................................................... 54 CARRIER ROLLER.................................................................................................. 56 TRACK ROLLER.................................................................................................... 57 TRACK SHOE...................................................................................................... 58 TRIPLE GROUSER SHOE............................................................................................. 61 HYDRAULIC EQUIPMENT LAYOUT DRAWING.............................................................................. 62 HYDRAULIC TANK.................................................................................................. 64 HYDRAULIC PUMP.................................................................................................. 66 HPV125 + 125................................................................................................ 66 LS VALVE.................................................................................................... 71 PC VALVE.................................................................................................... 71 LS(PC)-EPC VALVE............................................................................................ 84 VARIABLE VOLUME VALVE........................................................................................... 87 CONTROL VALVE................................................................................................... 90 MAIN RELIEF VALVE...........................................................................................104 VARIABLE PRESSURE COMPENSATION VALVE........................................................................105 CLSS............................................................................................................106 SELF PRESSURE REDUCING VALVE....................................................................................109 SWING MOTOR.....................................................................................................113 RELIEF VALVE PORTION........................................................................................116 SWING LOCK..................................................................................................117 REVERSE PREVENTION VALVE........................................................................................118 CENTER SWIVEL JOINT.............................................................................................121 TRAVEL MOTOR....................................................................................................123 PC300LC-7L..................................................................................................123 MOTOR OPERATION.........................................................................................126 PARKING BRAKE OPERATION.................................................................................128 PC300HD-7L..................................................................................................129 MOTOR OPERATION.........................................................................................131 PARKING BRAKE OPERATION.................................................................................133 BRAKE VALVE OPERATION.......................................................................................134 TRAVEL JUNCTION VALVE...........................................................................................139 TRAVEL PPC SHUTTLE VALVE........................................................................................142 VALVE CONTROL...................................................................................................146 WORK EQUIPMENT • SWING PPC VALVE................................................................................147 TRAVEL PPC VALVE................................................................................................153 SERVICE VALVE...................................................................................................162 SOLENOID VALVE..................................................................................................165 PPC ACCUMULATOR.................................................................................................167 RETURN OIL FILTER...............................................................................................168 FOR BREAKER.................................................................................................168 BOOM HYDRAULIC DRIFT PREVENTION VALVE...........................................................................170 QUICK RETURN VALVE..............................................................................................176 LIFT CHECK VALVE................................................................................................178 ATTACHMENT CIRCUIT SELECTOR VALVE...............................................................................179 HYDRAULIC CYLINDER..............................................................................................182 BOOM CYLINDER...............................................................................................182 ARM CYLINDER................................................................................................182 BUCKET CYLINDER.............................................................................................183 WORK EQUIPMENT..................................................................................................184 DIMENSION OF ARM............................................................................................186 DIMENSION OF BUCKET.........................................................................................188 AIR CONDITIONER.................................................................................................190 PIPING......................................................................................................190 ENGINE CONTROL..................................................................................................191 FUEL CONTROL DIAL...........................................................................................193 GOVERNOR MOTOR..............................................................................................194 ENGINE THROTTLE AND PUMP CONTROLLER.........................................................................196 INPUT AND OUTPUT SIGNALS................................................................................197 ELECTRONIC CONTROL SYSTEM.......................................................................................199 TOTAL SYSTEM DIAGRAM........................................................................................200 MULTI MONITOR SYSTEM............................................................................................223 MONITOR PANEL...............................................................................................224 MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION............................................................226 MAINTENANCE FUNCTION........................................................................................236 SENSORS.........................................................................................................241 ENGINE OIL LEVEL SENSOR.....................................................................................242 ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)...............................................................242 COOLANT TEMPERATURE SENSOR..................................................................................242 HYDRAULIC OIL TEMPERATURE SENSOR............................................................................242 FUEL LEVEL SENSOR...........................................................................................243 AIR CLEANER CLOGGING SENSOR.................................................................................243 20 TESTING, ADJUSTING AND TROUBLESHOOTING...........................................................................245 STANDARD VALUE TABLES...........................................................................................247 ENGINE RELATED..............................................................................................247 CHASSIS RELATED.............................................................................................248 TESTING AND ADJUSTING...........................................................................................257 SERVICE TOOLS...............................................................................................259 ENGINE......................................................................................................260 AIR BOOST PRESSURE......................................................................................260 AIR COMPRESSOR BELT TENSION.............................................................................260 BLOW-BY PRESSURE........................................................................................260 COMPRESSION PRESSURE....................................................................................260 ENGINE OIL PRESSURE.....................................................................................260 ENGINE RPM..............................................................................................260 ENGINE SPEED SENSOR.....................................................................................260 EXHAUST GAS COLOR.......................................................................................260 FUEL INJECTION TIMING...................................................................................260 VALVE CLEARANCE.........................................................................................260 EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE................................................................261 SWING CIRCLE BEARINGS.......................................................................................262 TRACK SHOE TENSION..........................................................................................263 SPROCKET....................................................................................................263 OIL PRESSURE................................................................................................264 WORK EQUIPMENT, SWING AND TRAVEL........................................................................264 CONTROL CIRCUIT.........................................................................................269 PUMP PC CONTROL CIRCUIT.................................................................................270 PUMP LS CONTROL CIRCUIT.................................................................................273 SOLENOID VALVE OUTPUT...................................................................................278 PPC VALVE OUTPUT........................................................................................281 WORK EQUIPMENT AND SWING PPC VALVE..........................................................................282 WORK EQUIPMENT, HYDRAULIC DRIFT LOCATIONS...................................................................283 RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT......................................................283 BOOM AND BUCKET CYLINDERS...............................................................................283 BOOM LOCK VALVE.........................................................................................284 ARM CYLINDER............................................................................................284 PPC VALVE...............................................................................................285 OIL LEAKAGE AMOUNT..........................................................................................286 BOOM CYLINDER...........................................................................................286 ARM CYLINDER............................................................................................286 BUCKET CYLINDER.........................................................................................287 SWING MOTOR.............................................................................................287 TRAVEL MOTOR............................................................................................288 AIR BLEEDING OF VARIOUS PARTS...............................................................................289 DIODE INSPECTION PROCEDURES.................................................................................291 MULTI-MONITOR PANEL.........................................................................................293 MONITOR PANEL FUNCTIONS.................................................................................294 OPERATOR’S MENU AND DISPLAY (OUTLINE)...................................................................295 TABLE FOR SERVICE AND FAILURE CODE NOS..................................................................300 SERVICE MENU............................................................................................302 WAY OF SWITCHING TO SERVICE MENU....................................................................302 TABLE FOR MONITORING ITEMS..........................................................................305 ELECTRICAL SYSTEM TROUBLESHOOTING PREPARTIONS...............................................................319 PC300HD-7L Serial No. A85049 and UP.........................................................................320 PC300LC-7L Serial No. A86675 and UP.........................................................................320 PM TUNE SERVICE.............................................................................................322 TROUBLESHOOTING GENERAL.........................................................................................327 TROUBLESHOOTING POINTS TO REMEMBER..........................................................................329 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................331 CARRYING OUT MAINTENANCE POINTS TO REMEMBER.................................................................332 CHECKS BEFORE TROUBLESHOOTING...............................................................................340 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING................................................................341 CONNECTOR TABLE.............................................................................................345 CONNECTOR LOCATION DIAGRAM..................................................................................356 PC300HD-7L Serial No. A85049 and UP.........................................................................364 PC300LC-7L Serial No. A86675 and UP.........................................................................364 CONNECTOR LOCATION DIAGRAM..............................................................................369 ELECTRICAL DIAGRAM FOLDOUTS.................................................................................375 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................376 TROUBLESHOOTING ELECTRICAL SYSTEM (E-MODE)......................................................................403 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM..............................................................407 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF...........................................407 USER CODE MEMORY RETENTION FUNCTION.....................................................................407 ERROR, FAILURE CODES AND POSSIBLE CAUSES....................................................................408 CONNECTION TABLE OF FUSE BOX................................................................................412 INFORMATION CONTAINED IN TESTING PROCEDURES.................................................................414 (E101)......................................................................................................416 ABNORMAL DATA IN ERROR HISTORY..........................................................................416 (E112)......................................................................................................420 SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION..................................................420 (E113)......................................................................................................422 SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION..................................................422 (E114)......................................................................................................424 SHORT OR OPEN IN WINDOW WASHER SYSTEM...................................................................424 (E115)......................................................................................................426 ABNORMAL WINDSHIELD WIPER MOTION........................................................................426 (E116)......................................................................................................428 ABNORMALITY IN PARKING WIPER ARM........................................................................428 (E201)......................................................................................................430 SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID...........................................................430 (E203)......................................................................................................434 SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM.....................................................434 (E204)......................................................................................................438 SHORT IN MERGE/DIVIDE SOLENOID..........................................................................438 (E205)......................................................................................................442 SHORT IN 2 STAGE RELIEF SOLENOID........................................................................442 (E206)......................................................................................................446 SHORT IN TRAVEL SPEED SHIFT SOLENOID....................................................................446 (E211)......................................................................................................450 OPEN IN TRAVEL INTERLOCKING SOLENOID....................................................................450 (E213)......................................................................................................454 OPEN IN SWING PARKING BRAKE SOLENOID....................................................................454 (E214)......................................................................................................458 OPEN OF MERGE/DIVIDE SOLENOID...........................................................................458 (E215)......................................................................................................462 OPEN IN 2 STAGE RELIEF SOLENOID.........................................................................462 (E216)......................................................................................................466 OPEN IN TRAVEL SPEED SOLENOID...........................................................................466 (E217)......................................................................................................470 ABNORMAL INPUT FOR MODEL CODE...........................................................................470 (E218)......................................................................................................472 OPEN IN S-NET SIGNAL....................................................................................472 (E222)......................................................................................................474 SHORT IN LS-EPC SOLENOID................................................................................474 (E223)......................................................................................................476 OPEN IN LS-EPC SOLENOID SYSTEM..........................................................................476 (E224)......................................................................................................478 ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL..................................................................478 (E225)......................................................................................................480 ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL..................................................................480 (E226)......................................................................................................482 ABNORMAL PRESSURE SENSOR POWER SUPPLY...................................................................482 (E227)......................................................................................................484 ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER..................................................484 (E228)......................................................................................................486 SHORT IN ATTACHMENT RETURN SWITCHING RELAY..............................................................486 (E232)......................................................................................................488 SHORT IN PC-EPC SOLENOID................................................................................488 (E233)......................................................................................................490 OPEN IN PC-EPC SOLENOID SYSTEM..........................................................................490 (E238)......................................................................................................492 OPEN IN ATTACHMENT RETURN SWITCH RELAY..................................................................492 (E245)......................................................................................................494 SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM............................................................494 (E246)......................................................................................................496 OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM.............................................................496 (E256)......................................................................................................498 INCORRECT NON-VOLATILE MEMORY DATA......................................................................498 (E304)......................................................................................................502 SHORT IN ENGINE STOP SOLENOID SYSTEM....................................................................502 (E314)......................................................................................................506 OPEN IN ENGINE STOP SOLENOID SYSTEM.....................................................................506 (E306)......................................................................................................508 ABNORMAL GOVERNOR POTENTIOMETER SIGNALS.................................................................508 (E308)......................................................................................................510 ABNORMAL FUEL DIAL SIGNALS..............................................................................510 (E315)......................................................................................................512 SHORT IN BATTERY RELAY SYSTEM...........................................................................512 (E316)......................................................................................................514 STEP OUT IN GOVERNOR MOTOR..............................................................................514 (E317)......................................................................................................516 OPEN IN GOVERNOR MOTOR PHASE “A” AND “B”................................................................516 (E318)......................................................................................................518 SHORT IN GOVERNOR MOTOR PHASE “A” AND “B”...............................................................518 (E501)......................................................................................................520 MODEL SELECTION FUNCTION NOT PROVIDED...................................................................520 (E502)......................................................................................................521 MODEL SELECTING SIGNAL FAULT............................................................................521 (AA10NX)....................................................................................................522 AIR CLEANER CLOG INDICATOR FAILURE......................................................................522 (AB00KE)....................................................................................................524 LOW CHARGING VOLTAGE INDICATED..........................................................................524 (B@BAZG)....................................................................................................526 ABNORMAL ENGINE OIL PRESSURE............................................................................526 (B@BAZK)....................................................................................................528 ABNORMAL ENGINE OIL LEVEL...............................................................................528 (B@BCNS)....................................................................................................530 ENGINE COOLANT INDICATING OVERHEAT CONDITION............................................................530 (B@BCZK)....................................................................................................532 ABNORMAL COOLANT LEVEL INDICATION.......................................................................532 (B@HANS)....................................................................................................534 HYDRAULIC OIL OVERHEAT INDICATION.......................................................................534 TROUBLESHOOTING MONITOR ELECTRICAL SYSTEM (E-MODE)..............................................................537 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM..............................................................539 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF...........................................539 USER CODE MEMORY RETENTION FUNCTION.....................................................................539 INFORMATION CONTAINED IN TESTING PROCEDURES.................................................................393 (E-1).......................................................................................................542 ENGINE WILL NOT CRANK...................................................................................542 (E-2).......................................................................................................544 ENGINE STOPS WHILE IN OPERATION.........................................................................544 (E-3).......................................................................................................546 ENGINE SPEED IRREGULAR, OR HUNTING......................................................................546 (E-4).......................................................................................................548 ENGINE DOES NOT SHUT DOWN...............................................................................548 (E-5).......................................................................................................550 AUTO DECELERATOR DOES NOT WORK..........................................................................550 (E-6).......................................................................................................551 AUTO ENGINE WARM UP DEVICE DOES NOT WORK................................................................551 (E-7).......................................................................................................552 COLD START PREHEATER DOES NOT WORK......................................................................552 (E-8).......................................................................................................554 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE.....................................................554 (E-9).......................................................................................................556 ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE.............................................................556 (E-10)......................................................................................................558 NO DISPLAY ON MONITOR PANEL.............................................................................558 (E-11)......................................................................................................560 PART OF DISPLAY ON MONITOR PANEL IS MISSING.............................................................560 (E-12)......................................................................................................561 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL.................................................561 (E-13)......................................................................................................562 FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL..............................................562 (E-14)......................................................................................................564 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY............................................564 (E-15)......................................................................................................566 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY..............................................566 (E-16)......................................................................................................568 FUEL GAUGE DOES NOT DISPLAY CORRECTLY...................................................................568 (E-17)......................................................................................................570 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY...........................................................570 (E-18)......................................................................................................572 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS.................................................572 (E-19)......................................................................................................574 WINDSHIELD WIPER DOES NOT WORK..........................................................................574 (E-20)......................................................................................................576 ALARM BUZZER CANNOT BE CANCELLED........................................................................576 (E-21)......................................................................................................578 BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR...........................................................578 (E-22)......................................................................................................580 BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR...........................................................580 (E-23)......................................................................................................582 ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR...........................................................582 (E-24)......................................................................................................584 ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR..........................................................584 (E-25)......................................................................................................586 BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR..........................................................586 (E-26)......................................................................................................588 BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR..........................................................588 (E-27)......................................................................................................590 SWING NOT CORRECTLY DISPLAYED ON MONITOR................................................................590 (E-28)......................................................................................................592 TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR...............................................................592 (E-29)......................................................................................................594 TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR.........................................594 (E-30)......................................................................................................596 SERVICE NOT CORRECTLY DISPLAYED ON MONITOR..............................................................596 (E-31)......................................................................................................598 AIR CONDITIONER SYSTEM DOES NOT WORK....................................................................598 (E-32)......................................................................................................616 TRAVEL ALARM DOES NOT SOUND.............................................................................616 TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSEM (H-MODE).........................................................619 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS...........................................................621 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................623 (H-1).......................................................................................................624 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW......................................624 (H-2).......................................................................................................625 ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS.............................................................625 (H-3).......................................................................................................626 NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT.............................................................626 (H-4).......................................................................................................626 ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP.............................................................626 (H-5).......................................................................................................627 AUTO-DECELERATOR DOES NOT WORK..........................................................................627 (H-6).......................................................................................................627 FINE CONTROL MODE DOES NOT FUNCTION.....................................................................627 (H-7)....................................................................................................... 0 BOOM MOVES SLOWLY OR LACKS POWER........................................................................628 (H-8).......................................................................................................629 ARM MOVES SLOWLY OR LACKS POWER.........................................................................629 (H-9).......................................................................................................630 BUCKET MOVES SLOWLY OR LACKS POWER......................................................................630 (H-10)......................................................................................................631 WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION......................................................631 (H-11)......................................................................................................632 WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT............................................................632 (H-12)......................................................................................................633 WORK EQUIPMENT HAS EXCESSIVE LAG TIME...................................................................633 (H-13)......................................................................................................634 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT..............................................634 (H-14)......................................................................................................634 ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE............................................................634 (H-15)......................................................................................................634 IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY..................................634 (H-16)......................................................................................................635 IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY....................................................635 (H-17)......................................................................................................635 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY...........................................................635 (H-18)......................................................................................................636 MACHINE SWERVES WHEN TRAVELING..........................................................................636 (H-19)......................................................................................................596 MACHINE TRAVELS SLOWLY..................................................................................637 (H-20)...................................................................................................... 0 MACHINE CANNOT BE STEERED EASILY OR LACKS POWER.........................................................638 (H-21)......................................................................................................639 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING..................................639 (H-22)......................................................................................................639 TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY)..............................................................639 (H-23)......................................................................................................640 MACHINE DOES NOT SWING..................................................................................640 (H-24)......................................................................................................641 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW......................................................641 (H-25)...................................................................................................... 0 EXCESSIVE OVERRUN WHEN STOPPING SWING...................................................................642 (H-26)......................................................................................................643 THERE IS A SUDDEN SHOCK WHEN STOPPING SWING.............................................................643 (H-27)......................................................................................................643 ABNORMAL NOISE CAUSED WHEN STOPPING SWING...............................................................643 (H-28)......................................................................................................644 SWING NATURAL DRIFT IS EXCESSIVE........................................................................644 30 DISASSEMBLY AND ASSEMBLY.........................................................................................645 METHOD OF USING MANUAL..........................................................................................649 PRECAUTIONS DURING OPERATION....................................................................................650 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK..................................................................263 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK.............................................................651 PRECAUTIONS WHEN COMPLETING THE OPERATIONS..................................................................652 OTHER PRECAUTIONS...........................................................................................652 SPECIAL TOOL LIST...............................................................................................653 SKETCHES OF SPECIAL TOOLS.......................................................................................656 ENGINE..........................................................................................................657 ALTERNATOR..................................................................................................657 CYLINDER HEAD...............................................................................................657 ENGINE FRONT SEAL...........................................................................................657 ENGINE OIL COOLER...........................................................................................657 ENGINE REAR SEAL............................................................................................657 FUEL INJECTION PUMP.........................................................................................657 NOZZLE HOLDER...............................................................................................657 STARTING MOTOR..............................................................................................657 THERMOSTAT..................................................................................................657 TURBOCHARGER................................................................................................657 WATER PUMP..................................................................................................657 RADIATOR........................................................................................................658 REMOVAL.....................................................................................................658 INSTALLATION................................................................................................659 HYDRAULIC OIL COOLER............................................................................................660 REMOVAL.....................................................................................................660 INSTALLATION................................................................................................661 ENGINE AND HYDRAULIC PUMPS......................................................................................662 REMOVAL.....................................................................................................276 INSTALLATION................................................................................................666 FINAL DRIVE.....................................................................................................667 REMOVAL.....................................................................................................667 INSTALLATION................................................................................................667 DISASSEMBLY.................................................................................................668 ASSEMBLY....................................................................................................672 SWING MOTOR AND SWING MACHINERY.................................................................................679 REMOVAL.....................................................................................................259 INSTALLATION................................................................................................680 DISASSEMBLY.................................................................................................681 ASSEMBLY....................................................................................................684 CARRIER ROLLER..................................................................................................689 ASSEMBLY....................................................................................................689 TRACK ROLLER....................................................................................................690 ASSEMBLY....................................................................................................690 IDLER...........................................................................................................691 DISASSEMBLY.................................................................................................691 ASSEMBLY....................................................................................................692 RECOIL SPRING...................................................................................................695 DISASSEMBLY.................................................................................................695 ASSEMBLY....................................................................................................696 SPROCKET........................................................................................................698 REMOVAL.....................................................................................................698 INSTALLATION................................................................................................698 TRACK SHOE......................................................................................................699 EXPANSION OF TRACK SHOE.....................................................................................699 ASSEMBLY....................................................................................................700 SWING CIRCLE....................................................................................................701 REMOVAL.....................................................................................................701 INSTALLATION................................................................................................701 REVOLVING FRAME.................................................................................................702 REMOVAL.....................................................................................................702 INSTALLATION................................................................................................704 CENTER SWIVEL JOINT.............................................................................................705 REMOVAL.....................................................................................................705 INSTALLATION................................................................................................706 DISASSEMBLY.................................................................................................707 ASSEMBLY....................................................................................................707 HYDRAULIC TANK..................................................................................................708 REMOVAL.....................................................................................................708 INSTALLATION................................................................................................709 CONTROL VALVE...................................................................................................262 REMOVAL.....................................................................................................710 INSTALLATION................................................................................................712 PROCEDURES FOR REPLACING PRESSURE COMPENSATION VALVE SEAL...................................................713 ASSEMBLY....................................................................................................714 HYDRAULIC PUMP..................................................................................................715 REMOVAL.....................................................................................................715 INSTALLATION................................................................................................717 INPUT SHAFT OIL SEAL........................................................................................718 REMOVAL.................................................................................................718 INSTALLATION............................................................................................718 WORK EQUIPMENT PPC VALVE........................................................................................719 ASSEMBLY....................................................................................................719 TRAVEL PPC VALVE................................................................................................720 ASSEMBLY....................................................................................................720 HYDRAULIC CYLINDER..............................................................................................721 DISASSEMBLY.................................................................................................721 ASSEMBLY....................................................................................................723 WORK EQUIPMENT..................................................................................................728 REMOVAL.....................................................................................................728 INSTALLATION................................................................................................730 AIR CONDITIONER.................................................................................................731 REMOVAL.....................................................................................................731 INSTALLATION................................................................................................734 COUNTERWEIGHT...................................................................................................735 REMOVAL.....................................................................................................735 INSTALLATION................................................................................................306 OPERATOR’S CAB..................................................................................................736 REMOVAL.....................................................................................................306 INSTALLATION................................................................................................738 MONITOR.........................................................................................................739 REMOVAL.....................................................................................................739 INSTALLATION................................................................................................739 GOVERNOR PUMP CONTROLLER........................................................................................740 REMOVAL.....................................................................................................740 INSTALLATION................................................................................................740 90 OTHERS...........................................................................................................741 ELECTRICAL......................................................................................................743 ELECTRICAL (PC300HD-7L SERIAL NO. A85001 THROUGH A85047 AND PC300LC-7L SERIAL NO. A85001 THROUGH A86673)....743 ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 3) FOLDOUT 1.........................................................743 ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 3) FOLDOUT 2.........................................................745 ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 3) FOLDOUT 3.........................................................747 ELECTRICAL DIAGRAM 2/4 (SHEET 1 OF 1) FOLDOUT 4.........................................................749 ELECTRICAL DIAGRAM 3/4 (SHEET 1 OF 2) FOLDOUT 5.........................................................751 ELECTRICAL DIAGRAM 3/4 (SHEET 2 OF 2) FOLDOUT 6.........................................................753 ELECTRICAL DIAGRAM 4/4 (SHEET 1 OF 2) FOLDOUT 7.........................................................755 ELECTRICAL DIAGRAM 4/4 (SHEET 2 OF 2) FOLDOUT 8.........................................................757 ELECTRICAL (PC300HD-7L SERIAL NO. A85049 AND UP/PC300LC-7L SERIAL NO. A86675 AND UP)........................759 ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 9) FOLDOUT 1.........................................................759 ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 9) FOLDOUT 2.........................................................761 ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 9) FOLDOUT 3.........................................................763 ELECTRICAL DIAGRAM 2/4 (SHEET 4 OF 9) FOLDOUT 1.........................................................765 ELECTRICAL DIAGRAM 3/4 (SHEET 5 OF 9) FOLDOUT 2.........................................................767 ELECTRICAL DIAGRAM 3/4 (SHEET 6 OF 9) FOLDOUT 3.........................................................769 ELECTRICAL DIAGRAM 4/4 (SHEET 7 OF 9) FOLDOUT 1.........................................................771 ELECTRICAL DIAGRAM 4/4 (SHEET 8 OF 9) FOLDOUT 2.........................................................773 ELECTRICAL DIAGRAM 4/4 (SHEET 9 OF 9) FOLDOUT 3.........................................................775 HYDRAULIC ......................................................................................................777 HYDRAULIC DIAGRAM (SHEET 1 OF 3) FOLDOUT 9..................................................................777 HYDRAULIC DIAGRAM (SHEET 2 OF 3) FOLDOUT 10.................................................................779 HYDRAULIC DIAGRAM (SHEET 3 OF 3) FOLDOUT 11.................................................................781
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
