Komatsu PC300LC-7L PC300HD-7L Hydraulic Excavator Shop Manual PDF

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Komatsu PC300LC-7L PC300HD-7L Hydraulic Excavator Shop Manual CEBM009105 – PDF DOWNLOAD

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Komatsu PC300LC-7L PC300HD-7L Hydraulic Excavator Shop Manual CEBM009105 – PDF DOWNLOAD 

Language : English
Pages : 782
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC300LC-7L PC300HD-7L Hydraulic Excavator Shop Manual CEBM009105 – PDF DOWNLOAD 

TABLE OF CONTENTS:

Komatsu PC300LC-7L PC300HD-7L Hydraulic Excavator Shop Manual CEBM009105 – PDF DOWNLOAD

MAIN MENU 0
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
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
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
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
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 0
ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 3) FOLDOUT 1 741

S.V 15/12/24