Complete service repair manual with Electrical Wiring Diagrams for Komatsu Logging/Road Builder Excavator Excavator GALEO PC300LC-7E0, PC300HD-7E0, PC300LL-7E0, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Logging/Road Builder Excavator Excavator GALEO PC300LC-7E0, PC300HD-7E0, PC300LL-7E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM016802 – Hydraulic Excavator GALEO PC300LC-7E0, PC300HD-7E0 Shop Manual.pdf
CEBM017800 – Logging_Road Builder Excavator GALEO PC300LL-7E0 Shop Manual.pdf
CEAM016902 – Hydraulic Excavator GALEO PC300LL-7E0, PC300HD-7E0 Operation & Maintenance Manual.pdf
CEAM017802 – Logging Excavator GALEO PC300LL-7E0 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,466 pages
File Format: PDF
Language: English
CEAM016902 – Hydraulic Excavator GALEO PC300LL-7E0, PC300HD-7E0 Operation & Maintenance Manual…2
COVER…2
INTRODUCTION…4
FOREWORD…5
SAFETY INFORMATION…6
INTRODUCTION…7
INTENDED USE…7
FEATURES…7
DIRECTIONAL REFFERENCE OF MACHINE…7
BREAKING IN A NEW MACHINE…8
PLATE LOCATIONS…8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…8
ENGINE SERIAL NUMBER PLATE…9
SERVICE METER LOCATION…9
TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR…10
TABLE OF CONTENTS…11
SAFETY…20
SAFETY AND WARNING DECALS…21
LOCATION OF THE SAFETY DECALS…21
SAFETY LABELS…22
GENERAL SAFETY RULES AND PRECAUTIONS…28
GENERAL SAFETY RULES…28
UNAUTHORIZED MODIFICATIONS…29
GENERAL SAFETY AT JOB SITE…29
WORKING ON LOOSE GROUND…29
SAFETY FEATURES…30
PERSONAL PROTECTIVE EQUIPMENT…30
FIRE AND EXPLOSION PREVENTION…31
FIRE CAUSED BY FUEL OR OIL…31
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL…31
FIRE COMING FROM ELECTRIC WIRING…32
FIRE COMING FROM HYDRAULIC LINE…32
WINDSHIELD WASHER FLUID…32
ACTION IF FIRE OCCURS…32
DUST HAZARD PRECAUTIONS…32
ASBESTOS HAZARD ALERT…33
KEEP OPERATOR'S COMPARTMENT CLEAN…33
LEAVING OPERATOR'S SEAT WITH LOCK…33
MOUNTING AND DISMOUNTING…34
FIRE EXTINGUISHER AND FIRST AID KIT…34
INSIDE OPERATOR’S COMPARTMENT…35
PROTECTION AGAINST FALLING OR FLYING OBJECTS…35
PRECAUTIONS FOR ATTACHMENTS…36
QUICK COUPLER ATTACHMENT…36
LARGE ATTACHMENTS AND COMBINATIONS…36
PRECAUTIONS BEFORE STARTING OPERATIONS…37
PRE-OPERATIONAL CHECKS…37
STARTING YOUR WORK OPERATIONS…37
WORK SITE HAZARDS…37
AVOIDING DANGEROUS SITUATIONS…38
DIGGING HARD ROCKY GROUND…41
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…41
WORKING CLEARANCES…42
OPERATIONS ON SLOPES…43
OPERATIONS ON SNOW…43
RULES FOR ROAD TRAVEL…44
TRAVELING WITH CARRAGE REVERSED…44
TRAVEL ON SLOPES…45
PARKING THE MACHINE…46
PRECAUTIONS DURING MAINTENANCE OPERATIONS…47
WARNING TAGS…47
EQUIPMENT STORAGE…47
WORKING UNDER THE MACHINE…48
USING DROP LAMPS…48
KEEPING THE MACHINE CLEAN…48
PERFORMING GENERAL MAINTENANCE PROCEDURES…49
RUNNING THE ENGINE DURING MAINTENANCE…50
PROPER TOOLS…50
WELDING, GRINDING OR CUTTING…51
ADJUSTING TRACK TENSION…51
DO NOT DISASSEMBLE RECOIL SPRINGS…51
WHEN USING HAMMER…51
RULES FOR REFUELING THE MACHINE…52
COOLING SYSTEM PRECAUTIONS…52
BATTERY PRECAUTIONS…53
STARTING ENGINE WITH BOOSTER CABLES…53
STARTING PRECAUTIONS…53
HIGH PRESSURE HOSES…54
SAFETY HANDLING HIGH-PRESSURE HOSES…54
PRECAUTION FOR HIGH FUEL PRESSURE…54
HIGH TEMPERATURES AREAS…54
DISPOSAL OF WASTE MATERIALS…55
ACCUMULATOR…55
CRITICAL PARTS…55
HIGH VOLTAGE…56
TOWING…56
SAFETY RULES FOR TOWING…56
OPERATION…58
GENERAL VIEWS…59
VIEW OF MACHINE…59
VIEW CONTROLS AND GAUGES…60
MACHINE MONITOR SYSTEM…61
MONITOR BEZEL LAYOUT…61
BASIC OPERATION OF MACHINE MONITOR…62
ABNORMALITY OCCURS WHEN STARTING THE ENGINE…63
ABNORMALITY OCCURS DURING OPERATION…64
COLOR WARNING OR ALERT SYSTEM…65
MONITOR CHECK ITEMS…66
EMERGENCY ALERTS…66
ENGINE COOLANT TEMPERATURE MONITOR…66
HYDRAULIC OIL TEMPERATURE MONITOR…67
ENGINE OIL PRESSURE MONITOR…67
WARNING ALERTS…68
ENGINE COOLANT TEMPERATURE MONITOR…68
HYDRAULIC OIL TEMPERATURE MONITOR…69
FUEL LEVEL MONITOR…69
CHARGE MONITOR…69
AIR CLEANER CLOGGING MONITOR…69
WATER SEPARATOR MONITOR…70
CHECK ALERTS…71
COOLANT LEVEL MONITOR…71
ENGINE OIL LEVEL MONITOR…72
MAINTENANCE INTERVAL MONITOR…72
METER DISPLAY…73
PILOT DISPLAYS…73
GAUGES…76
MONITOR SWITCHES…78
SWITCH LAYOUT VIEW…78
WORKING MODE SELECTOR SWITCH…79
AUTO-DECELERATION SWITCH…80
TRAVEL SPEED SELECTOR SWITCH…81
WIPER SWITCH…82
WINDOW WASHER SWITCH…82
MAINTENANCE SWITCH…83
SELECT SWITCH…85
BACK SWITCH…87
UP SWITCH, DOWN SWITCH…87
INPUT CONFIRMATION SWITCH…88
LIQUID CRYSTAL ADJUSTMENT SWITCH…88
ALARM BUZZER STOP SWITCH…89
CONSOLE CONTROL SWITCHES…90
SWITCH LAYOUT VIEW…90
IGNITION SWITCH…91
ENGINE SPEED CONTROL DIAL…91
CIGARETTE LIGHTER…91
SWING LOCK SWITCH…92
LAMP SWITCH…92
MACHINE PUSH-UP SWITCH…92
HORN SWITCH…93
POWER MAX SWITCH…93
CAB LAMP SWITCH…93
EMERGENCY PUMP DRIVE SWITCH…93
SWING BRAKE CANCEL SWITCH…94
CONTROL LEVERS AND PEDALS…95
LEVER LAYOUT VIEW…95
SAFETY LOCK LEVER…95
TRAVEL LEVERS…96
WORK EQUIPMENT CONTROL LEVER…97
WINDOW SYSTEM…98
CEILING WINDOW…98
WHEN OPENING…98
WHEN CLOSING…98
FRONT WINDOW…99
WHEN OPENING…99
WHEN CLOSING…101
REMOVING FRONT BOTTOM WINDOW…103
CAB EMERGENCY EXIT WINDOW…104
SAFETY LOCKS AND SECURITY…105
DOOR LOCK…105
CAP, COVER WITH LOCK…105
OPENING AND CLOSING CAP WITH LOCK…106
OPENING AND CLOSING COVER…106
LOCKABLE AREAS…106
ADDTIONAL FEATURES AND ACCESSORIES…108
HOT AND COOL BOX…108
STORAGE BOX WITH CUP HOLDER…108
ASHTRAY…108
AUTO-TEMP AIR CONDITIONER…109
GENERAL DESCRIPTION OF CONTROL PANEL…109
SUNLIGHT SENSOR…113
A/C SYSTEM OPERATION…113
PRECAUTIONS WHEN USING AIR CONDITIONER…120
MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…120
SELF-DIAGNOSTIC FUNCTION…120
RADIO…122
EXPLANATION OF FEATURES…122
CONTROLS ON RADIO…124
TOOLBOX…126
GREASE GUN HOLDER…126
AUXILIARY POWER PORTS…127
24V POWER SOURCE…127
12V POWER SOURCE (IF EQUIPPED)…127
FUSES AND FUSE LINKS…128
FUSES…128
FUSE CAPACITIES AND CIRCUIT NAMES…128
FUSIBLE LINK…129
PRECAUTIONS BEFORE STARTING WORK OPERATIONS…130
PRE-OPERATIONAL CHECKS…130
WALK-AROUND CHECKS…130
CHECKS BEFORE STARTING…131
ADJUSTMENTS BEFORE OPERATION…137
REARVIEW MIRRORS…138
SEAT BELT…139
SYSTEM “ON” CHECKS…140
STARTING THE ENGINE…143
NORMAL OR COLD START PROCEDURES…143
OPERATIONS AND CHECKS AFTER STARTING ENGINE…146
BREAKING IN THE MACHINE…146
WARMING UP ENGINE…146
WARMING UP HYDRAULIC EQUIPMENT…148
AFTER WARMING-UP OPERATIONS…152
STOPPING THE ENGINE…153
CHECK AFTER SHUTING OFF ENGINE…153
MOVING, STOPPING AND PARKING THE MACHINE…154
PREPARATIONS FOR MOVING THE MACHINE…154
TURNING THE MACHINE…155
TURNING THE MACHINE WHEN STOPPED…155
CHANGING DIRECTION OF THE MACHINE…156
COUNTER-ROTATION TURN (SPIN TURN)…157
SWINGING…157
GENERAL TRAVELING…158
TRAVELING OVER OBSTACLES…158
HIGH SPEED TRAVEL…158
PERMISSIBLE WATER DEPTH…158
TRAVELING ON SLOPES…159
TRAVELING DOWNHILL…160
ENGINE STOPPED ON SLOPE…160
PRECAUTIONS ON SLOPES…160
ESCAPING FROM MUD…160
ONE SIDE OF TRACK STUCK…161
BOTH SIDES OF TRACKS STUCK…161
MOVING MACHINE BACKWARD…161
STOPPING MACHINE…162
PARKING MACHINE…163
CLEARING THE MACHINES TRACKS…163
PARKING…163
MACHINE INSPECTION AFTER DAILY WORK…165
STARTING YOUR WORK OPERATIONS…166
AVOIDING DANGEROUS SITUATIONS…166
DIGGING HARD ROCKY GROUND…169
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…169
WORKING CLEARANCES…170
OPERATIONS ON SLOPES…170
OPERATIONS ON SNOW…171
WORK EQUIPMENT OVERVIEW…172
ARM CONTROL…172
SWING CONTROL…172
BOOM CONTROL…172
BUCKET CONTROL…172
OPERATING MODES…173
WORKING MODE…173
ONE-TOUCH POWER MAX. SWITCH…173
EXCAVATING PROCEDURES…174
WORK EQUIPMENT ANGLES…175
DITCHING WORK…175
LOADING WORK…175
SEVERE JOB CONDITIONS…175
REPLACING WORK IMPLEMENTS…176
BUCKET REPLACEMENT…176
TRANSPORTING THE MACHINE…178
LOADING AND UNLOADING A TRAILER…178
LOADING THE MACHINE…179
SECURING MACHINE…182
UNLOADING THE MACHINE…184
LIFTING THE MACHINE…186
TOWING THE MACHINE…188
LIGHTWEIGHT TOWING HOOK…188
COLD WEATHER OPERATION…189
FUEL AND LUBRICANTS…189
COOLING SYSTEM COOLANT…189
BATTERY…190
MONITOR…191
PRECAUTIONS ON PARTICULAR JOBSITES…192
DISCHARGED BATTERY…192
REMOVAL AND INSTALLATION OF BATTERY…193
BATTERY CHARGES…193
STARTING ENGINE WITH BOOSTER CABLES…194
GENERAL TROUBLESHOOTING…196
AFTER RUNNING OUT OF FUEL…196
PROCEDURE FOR BLEEDING AIR…196
PHENOMENA THAT ARE NOT FAILURES…196
ELECTRICAL SYSTEM PROBLEMS…197
CHASSIS PROBLEMS…198
ENGINE PROBLEMS…199
ELECTRONIC CONTROL SYSTEM…200
MACHINE MONITOR TROUBLE DISPLAY…200
TELEPHONE WHEN ERROR OCCURS…201
LONG TERM STORAGE…202
BEFORE STORAGE…202
DURING STORAGE…202
AFTER STORAGE…202
STARTING MACHINE…202
MAINTENANCE…204
MAINTENANCE INFORMATION…205
SERVICE METER READING…205
KOMATSU GENUINE REPLACEMENT PARTS…205
KOMATSU GENUINE LUBRICANTS…205
WINDSHIELD WASHER FLUID…205
FRESH AND CLEAN LUBRICANTS…205
CHECK DRAINED OIL AND USED FILTER…205
FUEL STRAINER…205
WELDING INSTRUCTIONS…205
DO NOT DROP THINGS INSIDE MACHINE…205
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE…205
DUSTY JOBSITE…206
AVOID MIXING LUBRICANTS…206
LOCKING THE INSPECTION COVERS…206
HYDRAULIC SYSTEM – AIR BLEEDING…206
HYDRAULIC HOSE INSTALLATION…206
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS…206
LUBRICANTS, COOLANT AND FILTERS…207
OUTLINE OF SERVICE…207
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…207
OIL…207
FUEL…208
COOLANT AND WATER FOR DILUTION…208
GREASE…208
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)…209
OIL AND FUEL STORAGE…209
FILTERS…210
ELECTRIC SYSTEM MAINTENANCE…211
HANDLING HYDRAULIC SYSTEM…211
WEAR PARTS LIST…212
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…213
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS…215
TIGHTENING TORQUE SPECIFICATIONS…216
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…217
SAFETY RELATED CRITICAL PARTS…218
MAINTENANCE SCHEDULE…219
MAINTENANCE SCHEDULE CHART…219
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…221
REPLACE HYDRAULIC FILTER ELEMENT…221
CHANGE OIL IN HYDRAULIC TANK…221
REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER (IF EQUIPPED)…221
MAINTENANCE PROCEDURE…222
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…222
WHEN REQUIRED…223
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…223
CLEAN INSIDE OF COOLING SYSTEM…228
CHECK AND TIGHTEN TRACK SHOE BOLTS…231
CHECK AND ADJUST TRACK TENSION…232
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…234
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…237
REPLACE BUCKET SIDE CUTTER, SHROUD…238
ADJUST BUCKET CLEARANCE…239
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…240
CHECK AND ADJUST AIR CONDITIONER…241
CLEANING CAB FLOOR…242
SETTING MACHINE AT AN ANGLE…244
BLEEDING AIR FROM HYDRAULIC SYSTEM…245
CHECK BEFORE STARTING…247
EVERY 50 HOURS MAINTENANCE…248
LUBRICATING…248
EVERY 250 HOURS MAINTENANCE…249
LUBRICATE SWING CIRCLE…249
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL…249
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…250
CHECK LEVEL OF BATTERY ELECTROLYTE…251
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…253
EVERY 500 HOURS MAINTENANCE…254
LUBRICATING…254
REPLACE FUEL PRE-FILTER CARTRIDGE…255
CHECK SWING PINION GREASE LEVEL, ADD GREASE…258
CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTER CARTRIDGE…259
CLEAN/INSPECT RADIATOR, OIL COOLER, AFTERCOOLER AND CONDENSER FINS…260
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…262
REPLACE VENT ELEMENT IN HYDRAULIC TANK…263
EVERY 1000 HOURS MAINTENANCE…264
REPLACE FUEL MAIN FILTER CARTRIDGE…264
REPLACE HYDRAULIC OIL FILTER ELEMENT…266
CHANGE OIL IN SWING MACHINERY CASE…267
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…268
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS…268
REPLACE CORROSION RESISTOR CARTRIDGE (IF EQUIPPED)…269
CHECK FAN BELT AND ALTERNATOR DRIVE BELT TENSION, REPLACE…269
REPLACE HYDRAULIC TANK ADDITIONAL VENT ELEMENT…270
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)…270
EVERY 2000 HOURS MAINTENANCE…271
CHANGE OIL IN FINAL DRIVE CASE…271
CLEAN HYDRAULIC TANK STRAINER…272
CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)…273
CHECKING FUNCTION OF ACCUMULATOR…274
RELEASING PRESSURE IN HYDRAULIC CIRCUIT…275
CHECK ALTERNATOR, STARTING MOTOR…276
CHECK ENGINE VALVE CLEARANCE, ADJUST…276
CHECK VIBRATION DAMPER…276
EVERY 4000 HOURS MAINTENANCE…277
CHECK WATER PUMP…277
CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)…278
CHECK HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER…279
CHECK FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…279
EVERY 5000 HOURS MAINTENANCE…280
CHANGE OIL IN HYDRAULIC TANK…280
EVERY 8000 HOURS MAINTENANCE…281
REPLACE HIGH-PRESSURE PIPING CLAMP…281
REPLACE FUEL SPRAY PREVENTION CAP…281
SPECIFICATIONS…284
SPECIFICATIONS…285
OPTIONS, ATTACHMENTS…288
GENERAL PRECAUTIONS…289
PRECAUTIONS RELATED TO SAFETY…289
PRECAUTIONS FOR ATTACHMENT REMOVAL AND INSTALLATION…289
PRECAUTIONS WHEN USING LARGE IMPLEMENTS…290
HANDLING BUCKET WITH HOOK…291
HOOK CONDITION…291
PROHIBITED OPERATIONS…291
MACHINES READY FOR ATTACHMENTS…292
EXPLANATION OF COMPONENTS…292
STOP VALVE…292
SELECTOR VALVE…293
ATTACHMENT CONTROL PEDAL…293
LOCK PIN…293
BREAKER CIRCUIT ADDITIONAL OIL FILTER…294
HYDRAULIC CIRCUIT…296
SWITCHING THE HYDRAULIC CIRCUIT…296
ADJUSTING OIL FLOW…296
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT…296
HYDRAULIC CIRCUIT CONNECTION…297
OIL FLOW…298
REPLACE ADDITIONAL BREAKER FILTER ELEMENT…299
ATTACHMENT INSTALLATION AND REMOVAL PROCEDURE…300
REMOVAL PROCEDURE…300
INSTALLATION PROCEDURE…301
ATTACHMENT OPERATIONS…302
WHEN USING BREAKER…302
WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER…302
LONG TERM STORAGE…303
SPECIFICATIONS…303
ATTACHMENT GUIDE…304
COMBINATIONS OF WORK EQUIPMENT…304
SELECTION OF TRACK SHOES…306
SELECTING SHOES…306
HYDRAULIC BREAKER…307
MAIN APPLICATIONS…307
PROHIBITED OPERATIONS…309
GREASING…311
CEAM017802 – Logging Excavator GALEO PC300LL-7E0 Operation & Maintenance Manual…312
COVER…312
INTRODUCTION…316
FOREWORD…317
SAFETY INFORMATION…318
INTRODUCTION…319
INTENDED USE…319
FEATURES…319
DIRECTIONAL REFFERENCE OF MACHINE…319
BREAKING IN A NEW MACHINE…320
PLATE LOCATIONS…320
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…320
KOMATSU FORESTRY FRONT S/N PLATE…321
ENGINE SERIAL NUMBER PLATE…322
SERVICE METER LOCATION…322
TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR…323
TABLE OF CONTENTS…324
SAFETY…334
SAFETY AND WARNING DECALS…335
NORMAL EXCAVATOR DECALS…335
SAFETY LABELS…336
UNIQUE SAFETY DECALS FOR LOG LOADER AND ROAD BUILDER EXCAVATORS…342
GENERAL SAFETY RULES AND PRECAUTIONS…347
GENERAL SAFETY RULES…347
UNAUTHORIZED MODIFICATIONS…348
GENERAL SAFETY AT JOB SITE…348
WORKING ON LOOSE GROUND…348
SAFETY FEATURES…349
PERSONAL PROTECTIVE EQUIPMENT…349
FIRE AND EXPLOSION PREVENTION…349
FIRE CAUSED BY FUEL OR OIL…350
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL…350
FIRE COMING FROM ELECTRIC WIRING…351
FIRE COMING FROM HYDRAULIC LINE…351
WINDSHIELD WASHER FLUID…351
ACTION IF FIRE OCCURS…351
DUST HAZARD PRECAUTIONS…351
ASBESTOS HAZARD ALERT…352
KEEP OPERATOR'S COMPARTMENT CLEAN…352
LEAVING OPERATOR'S SEAT WITH LOCK…352
MOUNTING AND DISMOUNTING…353
FIRE EXTINGUISHER AND FIRST AID KIT…353
INSIDE OPERATOR’S COMPARTMENT…354
PROTECTION AGAINST FALLING OR FLYING OBJECTS…354
PRECAUTIONS FOR ATTACHMENTS…355
QUICK COUPLER ATTACHMENT…355
LARGE ATTACHMENTS AND COMBINATIONS…355
PRECAUTIONS BEFORE STARTING OPERATIONS…356
PRE-OPERATIONAL CHECKS…356
STARTING YOUR WORK OPERATIONS…356
WORK SITE HAZARDS…356
AVOIDING DANGEROUS SITUATIONS…357
DIGGING HARD ROCKY GROUND…360
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…360
WORKING CLEARANCES…361
OPERATIONS ON SLOPES…362
OPERATIONS ON SNOW…362
RULES FOR ROAD TRAVEL…363
TRAVELING WITH CARRAGE REVERSED…363
TRAVEL ON SLOPES…364
SHIPPING THE MACHINE…365
PARKING THE MACHINE…366
PRECAUTIONS DURING MAINTENANCE OPERATIONS…367
WARNING TAGS…367
EQUIPMENT STORAGE…367
WORKING UNDER THE MACHINE…368
USING DROP LAMPS…368
KEEPING THE MACHINE CLEAN…368
PERFORMING GENERAL MAINTENANCE PROCEDURES…369
RUNNING THE ENGINE DURING MAINTENANCE…370
PROPER TOOLS…370
WELDING, GRINDING OR CUTTING…371
ADJUSTING TRACK TENSION…371
DO NOT DISASSEMBLE RECOIL SPRINGS…371
WHEN USING HAMMER…371
RULES FOR REFUELING THE MACHINE…372
COOLING SYSTEM PRECAUTIONS…372
BATTERY PRECAUTIONS…373
STARTING ENGINE WITH BOOSTER CABLES…373
STARTING PRECAUTIONS…373
HIGH PRESSURE HOSES…374
SAFETY HANDLING HIGH-PRESSURE HOSES…374
PRECAUTION FOR HIGH FUEL PRESSURE…374
HIGH TEMPERATURES AREAS…375
DISPOSAL OF WASTE MATERIALS…375
ACCUMULATOR…375
CRITICAL PARTS…376
HIGH VOLTAGE…376
TOWING…376
SAFETY RULES FOR TOWING…376
OPERATION…378
GENERAL VIEWS…379
GENERAL VIEW OF LOG LOADER MACHINE…379
GENERAL VIEW OF ROAD BUILDER MACHINE…380
VIEW CONTROLS AND GAUGES…381
MACHINE MONITOR SYSTEM…382
MONITOR LAYOUT…382
BASIC OPERATION OF MACHINE MONITOR…383
ABNORMALITY OCCURS WHEN STARTING THE ENGINE…384
ABNORMALITY OCCURS DURING OPERATION…385
COLOR WARNING OR ALERT SYSTEM…386
MONITOR CHECK ITEMS…387
EMERGENCY ALERTS…387
ENGINE COOLANT TEMPERATURE MONITOR…387
HYDRAULIC OIL TEMPERATURE MONITOR…388
ENGINE OIL PRESSURE MONITOR…388
WARNING ALERTS…389
ENGINE COOLANT TEMPERATURE MONITOR…389
HYDRAULIC OIL TEMPERATURE MONITOR…390
FUEL LEVEL MONITOR…390
CHARGE MONITOR…390
AIR CLEANER CLOGGING MONITOR…390
WATER SEPARATOR MONITOR…391
CHECK ALERTS…392
COOLANT LEVEL MONITOR…392
ENGINE OIL LEVEL MONITOR…393
MAINTENANCE INTERVAL MONITOR…393
METER DISPLAY…394
PILOT DISPLAYS…394
GAUGES…397
MONITOR SWITCHES…399
SWITCH LAYOUT VIEW…399
WORKING MODE SELECTOR SWITCH…400
AUTO-DECELERATION SWITCH…401
TRAVEL SPEED SELECTOR SWITCH…402
WIPER SWITCH…403
WINDOW WASHER SWITCH…403
MAINTENANCE SWITCH…404
SELECT SWITCH…406
BACK SWITCH…408
UP SWITCH, DOWN SWITCH…408
INPUT CONFIRMATION SWITCH…409
LIQUID CRYSTAL ADJUSTMENT SWITCH…409
ALARM BUZZER STOP SWITCH…410
CONSOLE CONTROL SWITCHES…411
SWITCH LAYOUT VIEW…411
IGNITION SWITCH…413
ENGINE SPEED CONTROL DIAL…413
CIGARETTE LIGHTER…413
SWING LOCK SWITCH…414
LAMP SWITCH…414
MACHINE PUSH-UP SWITCH…414
HORN SWITCH…415
LOG LOADER GRAPPLE ROTATION CW SWITCH…415
LOG LOADER GRAPPLE CLOSE SWITCH…415
POWER MAX SWITCH…415
LOG LOADER GRAPPLE ROTATION CCW SWITCH…415
LOG LOADER GRAPPLE OPEN SWITCH…415
CAB LAMP SWITCH…416
EMERGENCY PUMP DRIVE SWITCH…416
SWING BRAKE CANCEL SWITCH…416
CONTROL LEVERS AND PEDALS…417
LEVER LAYOUT VIEW…417
SAFETY LOCK LEVER…418
TRAVEL LEVERS…418
WORK EQUIPMENT CONTROL LEVER…419
WINDOW SYSTEM…420
CEILING WINDOW…420
WHEN OPENING…420
WHEN CLOSING…420
FRONT WINDOW…421
WHEN OPENING…421
WHEN CLOSING…424
REMOVING FRONT BOTTOM WINDOW…425
CAB EMERGENCY EXIT WINDOW…426
SAFETY LOCKS AND SECURITY…427
DOOR LOCK…427
CAP, COVER WITH LOCK…427
OPENING AND CLOSING CAP WITH LOCK…428
OPENING AND CLOSING COVER…428
LOCKABLE AREAS…429
ADDTIONAL FEATURES AND ACCESSORIES…430
HOT AND COOL BOX…430
STORAGE BOX WITH CUP HOLDER…430
ASHTRAY…430
AUTO-TEMP AIR CONDITIONER…431
GENERAL DESCRIPTION OF CONTROL PANEL…431
SUNLIGHT SENSOR…435
A/C SYSTEM OPERATION…435
PRECAUTIONS WHEN USING AIR CONDITIONER…442
MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…442
SELF-DIAGNOSTIC FUNCTION…442
RADIO…444
EXPLANATION OF FEATURES…444
CONTROLS ON RADIO…446
TOOLBOX…448
GREASE GUN HOLDER…448
AUXILIARY POWER PORTS…449
24V POWER SOURCE…449
12V POWER SOURCE (IF EQUIPPED)…449
FUSES AND FUSE LINKS…450
FUSES…450
FUSE CAPACITIES AND CIRCUIT NAMES…450
FUSIBLE LINK…451
HANDLING THE ACCUMULATOR…452
RELEASING PRESSURE IN CONTROL CIRCUIT…452
PRECAUTIONS BEFORE STARTING WORK OPERATIONS…453
PRE-OPERATIONAL CHECKS…453
WALK-AROUND CHECKS…453
CHECKS BEFORE STARTING…454
ADJUSTMENTS BEFORE OPERATION…461
REAR VIEW MIRRORS…462
SEAT BELT…463
SYSTEM “ON” CHECKS…464
STARTING THE ENGINE…467
NORMAL OR COLD START PROCEDURES…467
OPERATIONS AND CHECKS AFTER STARTING ENGINE…470
BREAKING IN THE MACHINE…470
WARMING UP ENGINE…470
WARMING UP HYDRAULIC EQUIPMENT…472
AFTER WARMING-UP OPERATIONS…477
STOPPING THE ENGINE…478
CHECK AFTER SHUTING OFF ENGINE…478
MOVING, STOPPING AND PARKING THE MACHINE…479
PREPARATIONS FOR MOVING THE MACHINE…479
MOVING MACHINE…480
TURNING THE MACHINE…481
TURNING THE MACHINE WHEN STOPPED…481
CHANGING DIRECTION OF THE MACHINE…482
COUNTER-ROTATION TURN (SPIN TURN)…482
SWINGING…483
GENERAL TRAVELING…484
TRAVELING OVER OBSTACLES…484
HIGH SPEED TRAVEL…484
PERMISSIBLE WATER DEPTH…484
TRAVELING ON SLOPES…485
TRAVELING DOWNHILL…486
ENGINE STOPPED ON SLOPE…486
PRECAUTIONS ON SLOPES…486
ESCAPING FROM MUD…486
ONE SIDE OF TRACK STUCK…486
BOTH SIDES OF TRACKS STUCK…487
MOVING MACHINE BACKWARD…487
STOPPING MACHINE…488
PARKING MACHINE…489
CLEARING THE MACHINES TRACKS…489
PARKING…490
MACHINE INSPECTION AFTER DAILY WORK…492
STARTING YOUR WORK OPERATIONS…493
AVOIDING DANGEROUS SITUATIONS…493
DIGGING HARD ROCKY GROUND…496
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…496
WORKING CLEARANCES…497
OPERATIONS ON SLOPES…497
OPERATIONS ON SNOW…498
WORK EQUIPMENT OVERVIEW…499
ARM CONTROL…499
SWING CONTROL…499
BOOM CONTROL…499
BUCKET OR HEEL RACK CONTROL…499
OPERATING MODES…500
WORKING MODE…500
ONE-TOUCH POWER MAX. SWITCH…500
EXCAVATING PROCEDURES…501
WORK EQUIPMENT ANGLES…501
DITCHING WORK…501
LOADING WORK…502
SEVERE JOB CONDITIONS…502
REPLACING WORK IMPLEMENTS…503
BUCKET REPLACEMENT…503
TRANSPORTING THE MACHINE…505
LOADING AND UNLOADING A TRAILER…505
LOADING THE MACHINE…506
SECURING MACHINE…510
UNLOADING THE MACHINE…514
LIFTING THE MACHINE…517
TOWING THE MACHINE…519
LIGHTWEIGHT TOWING HOOK…519
COLD WEATHER OPERATION…520
FUEL AND LUBRICANTS…520
COOLING SYSTEM COOLANT…520
BATTERY…521
MONITOR…522
PRECAUTIONS ON PARTICULAR JOBSITES…523
DISCHARGED BATTERY…523
REMOVAL AND INSTALLATION OF BATTERY…524
BATTERY CHARGES…524
STARTING ENGINE WITH BOOSTER CABLES…525
GENERAL TROUBLESHOOTING…527
AFTER RUNNING OUT OF FUEL…527
PROCEDURE FOR BLEEDING AIR…527
PHENOMENA THAT ARE NOT FAILURES…527
ELECTRICAL SYSTEM PROBLEMS…528
CHASSIS PROBLEMS…529
ENGINE PROBLEMS…530
ELECTRONIC CONTROL SYSTEM…531
MACHINE MONITOR TROUBLE DISPLAY…531
TELEPHONE WHEN ERROR OCCURS…532
LONG TERM STORAGE…533
BEFORE STORAGE…533
DURING STORAGE…533
AFTER STORAGE…534
STARTING MACHINE…534
MAINTENANCE…536
MAINTENANCE INFORMATION…537
SERVICE METER READING…537
KOMATSU GENUINE REPLACEMENT PARTS…537
KOMATSU GENUINE LUBRICANTS…537
WINDSHIELD WASHER FLUID…537
FRESH AND CLEAN LUBRICANTS…537
CHECK DRAINED OIL AND USED FILTER…537
FUEL STRAINER…537
WELDING INSTRUCTIONS…537
DO NOT DROP THINGS INSIDE MACHINE…537
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE…537
DUSTY JOBSITE…538
AVOID MIXING LUBRICANTS…538
LOCKING THE INSPECTION COVERS…538
HYDRAULIC SYSTEM – AIR BLEEDING…538
HYDRAULIC HOSE INSTALLATION…538
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS…538
LUBRICANTS, COOLANT AND FILTERS…539
OUTLINE OF SERVICE…539
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…539
OIL…539
FUEL…540
COOLANT AND WATER FOR DILUTION…540
GREASE…540
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)…541
OIL AND FUEL STORAGE…541
FILTERS…542
ELECTRIC SYSTEM MAINTENANCE…542
HANDLING HYDRAULIC SYSTEM…542
WEAR PARTS LIST…543
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…544
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS…546
TIGHTENING TORQUE SPECIFICATIONS…547
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…548
SAFETY RELATED CRITICAL PARTS…549
MAINTENANCE SCHEDULE…550
MAINTENANCE SCHEDULE CHART…550
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…552
REPLACE HYDRAULIC FILTER ELEMENT…552
CHANGE OIL IN HYDRAULIC TANK…552
REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER (IF EQUIPPED)…552
MAINTENANCE PROCEDURE…553
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…553
WHEN REQUIRED…554
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…554
CLEAN INSIDE OF COOLING SYSTEM…559
CHECK AND TIGHTEN TRACK SHOE BOLTS…562
CHECK AND ADJUST TRACK TENSION…563
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…565
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…568
REPLACE BUCKET SIDE CUTTER, SHROUD…569
ADJUST BUCKET CLEARANCE…570
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…571
CHECK AND ADJUST AIR CONDITIONER…572
CLEANING CAB FLOOR…573
SETTING MACHINE AT AN ANGLE…575
BLEEDING AIR FROM HYDRAULIC SYSTEM…576
CHECK BEFORE STARTING…578
EVERY 50 HOURS MAINTENANCE…579
LUBRICATING ROAD BUILDER…579
EVERY 250 HOURS MAINTENANCE…581
LUBRICATE SWING CIRCLE…581
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL…581
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…582
CHECK LEVEL OF BATTERY ELECTROLYTE…583
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…585
EVERY 500 HOURS MAINTENANCE…586
LUBRICATING…586
REPLACE FUEL PRE-FILTER CARTRIDGE…587
CHECK SWING PINION GREASE LEVEL, ADD GREASE…590
CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTER CARTRIDGE…591
CLEAN/NSPECT RADIATOR, OIL COOLER, AFTERCOOLER AND CONDENSER FINS…592
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…594
REPLACE VENT ELEMENT IN HYDRAULIC TANK…595
EVERY 1000 HOURS MAINTENANCE…596
REPLACE FUEL MAIN FILTER CARTRIDGE…596
REPLACE HYDRAULIC OIL FILTER ELEMENT…598
CHANGE OIL IN SWING MACHINERY CASE…599
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…600
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS…600
REPLACE CORROSION RESISTOR CARTRIDGE…601
CHECK FAN BELT AND ALTERNATOR DRIVE BELT TENSION, REPLACE…601
REPLACE HYDRAULIC TANK ADDITIONAL VENT ELEMENT…602
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)…602
EVERY 2000 HOURS MAINTENANCE…603
CHANGE OIL IN FINAL DRIVE CASE…603
CLEAN HYDRAULIC TANK STRAINER…604
CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)…605
CHECKING FUNCTION OF ACCUMULATOR…606
RELEASING PRESSURE IN HYDRAULIC CIRCUIT…607
CHECK ALTERNATOR, STARTING MOTOR…608
CHECK ENGINE VALVE CLEARANCE, ADJUST…608
CHECK VIBRATION DAMPER…608
EVERY 4000 HOURS MAINTENANCE…609
CHECK WATER PUMP…609
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)…610
CHECK HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER…611
CHECK FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…611
EVERY 5000 HOURS MAINTENANCE…612
CHANGE OIL IN HYDRAULIC TANK…612
EVERY 8000 HOURS MAINTENANCE…613
REPLACE HIGH-PRESSURE PIPING CLAMP…613
REPLACE FUEL SPRAY PREVENTION CAP…613
SPECIFICATIONS…614
SPECIFICATIONS…615
DIMENSIONS…615
WORKING RANGE…619
ROAD BUILDER…619
LOG LOADER…621
LIFTING CAPACITY…623
OPTIONS, ATTACHMENTS…630
GENERAL PRECAUTIONS…631
PRECAUTIONS RELATED TO SAFETY…631
PRECAUTIONS FOR ATTACHMENT REMOVAL AND INSTALLATION…631
PRECAUTIONS WHEN USING LARGE IMPLEMENTS…632
HANDLING BUCKET WITH HOOK…633
HOOK CONDITION…633
PROHIBITED OPERATIONS…633
COMBINATIONS OF WORK EQUIPMENT FOR PC300LC-7…634
SELECTION OF TRACK SHOES…635
CEBM016802 – Hydraulic Excavator GALEO PC300LC-7E0, PC300HD-7E0 Shop Manual…638
COVER…638
FOREWARD…639
CONTENTS…639
SAFETY…648
SAFETY NOTICE…648
IMPORTANT SAFETY NOTICE…648
GENERAL PRECAUTIONS…648
PREPARATIONS FOR WORK…648
PRECAUTIONS DURING WORK…648
GENERAL…650
HOW TO READ THE SHOP MANUAL…651
VOLUMES…651
DISTRIBUTION AND UPDATING…651
FILING METHOD…651
REVISED EDITION MARK…651
REVISIONS…651
SYMBOLS…651
HOISTING INSTRUCTIONS…652
HOISTING…652
WIRE ROPES…652
PUSH PULL COUPLER…653
TYPE 1…653
DISCONNECTION…653
CONNECTION…653
TYPE 2…654
DISCONNECTION…654
CONNECTION…654
TYPE 3…655
DISCONNECTION…655
CONNECTION…655
EXPLANATION OF MAINTENANCE STANDARD TERMS…656
STANDARD TIGHTENING TORQUE…658
BOLTS AND NUTS…658
TIGHTENING TORQUE OF HOSE NUTS…659
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…659
TIGHTENING TORQUE FOR FLARED NUTS…659
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS…660
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS…660
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)…660
ELECTRIC WIRE CODE…661
CLASSIFICATION BY THICKNESS…661
CLASSIFICATION BY COLOR AND CODE…661
HOW TO READ ELECTRIC WIRE CODE…662
CONVERSION TABLES…665
METHOD OF USING THE CONVERSION TABLE…665
COATING MATERIALS…671
01 GENERAL…673
SPECIFICATIONS…674
DIMENSIONS…674
WORKING RANGES…675
SPECIFICATIONS…676
WEIGHT TABLE…678
FUEL, COOLANT, AND LUBRICANTS…680
10 STRUCTURE AND FUNCTION…682
ENGINE RELATED PARTS…687
RADIATOR . OIL COOLER . AFTERCOOLER…688
FINAL DRIVE…690
PC300LC-7E0 MODEL…690
PC300HD-7E0 MODEL…692
SPROCKET…694
PC300LC-7E0 MODEL…694
SPROCKET TOOL…695
PC300HD-7E0 MODEL…696
SPROCKET TOOL…697
SWING MACHINERY…698
SWING CIRCLE…700
TRACK FRAME . RECOIL SPRING…701
PC300LC-7E0…701
PC300HD-7E0…703
IDLER…705
PC300LC-7E0 MODEL…705
PC300HD-7E0 MODEL…707
CARRIER ROLLER…709
PC300LC-7E0 MODEL…709
PC300HD-7E0 MODEL…711
TRACK ROLLER…713
PC300LC-7E0 MODEL…713
PC300HD-7E0 MODEL…715
TRACK SHOE…717
PC300LC-7E0 MODEL…717
PC300HD-7E0 MODEL…720
TRIPLE GROUSER SHOE…723
PC300LC-7E0 MODEL…723
PC300HD-7E0 MODEL…724
HYDRAULIC EQUIPMENT…725
HYDRAULIC TANK AND FILTER…727
HYDRAULIC PUMP…728
HPV125 + 125…728
FUNCTION…731
STRUCTURE…731
OPERATION…732
LS VALVE…734
FUNCTION…734
OPERATION…735
PC VALVE…739
FUNCTION…739
OPERATION…740
OUTLINE…742
OPERATION…742
LS(PC)-EPC Valve…746
FUNCTION…747
OPERATION…747
VARIABLE VOLUME VALVE…749
FUNCTION…749
OPERATION…749
CONTROL VALVE…750
OUTLINE…750
CLSS…762
OUTLINE OF CLSS…762
FEATURES…762
STRUCTURE…762
BASIC PRINCIPLE…763
VALVE FUNCTIONS AND OPERATION…766
UNLOADER VALVE…768
FUNCTION…768
OPERATION…768
INTRODUCTION OF LS PRESSURE…770
FUNCTION…770
OPERATION…770
LS BYPASS VALVE…771
FUNCTION…771
PRESSURE COMPENSATION VALVE…772
FUNCTION…772
FUNCTION…773
OPERATION…773
FUNCTION…774
PRESSURE COMPENSATION VALVE INNER SHUTTLE…775
FUNCTION…775
OUTLINE…776
BOOM REGENERATION CIRCUIT…777
FUNCTION…777
OPERATION…777
FUNCTION…778
ARM REGENERATION CIRCUIT…779
FUNCTION…779
OPERATION…779
FUNCTION…780
MERGE-DIVIDER VALVE…781
FUNCTION…781
OPERATION…781
OPERATION…782
LS SELECT VALVE…783
FUNCTION…783
OPERATION…783
SELF PRESSURE REDUCING VALVE…784
FUNCTION…784
OPERATION…784
TRAVEL JUNCTION VALVE…787
FUNCTION…787
OPERATION…787
OPERATION…788
TRAVEL PPC SHUTTLE VALVE…789
FUNCTION…789
OPERATION…789
OPERATION…790
BOOM DRIFT PREVENTION VALVE…791
FUNCTION…791
OPERATION…791
OPERATION…792
OPERATION…793
ARM DRIFT PREVENTION VALVE…794
FUNCTION…794
OPERATION…794
OPERATION…795
OPERATION…796
QUICK RETURN VALVE…798
FUNCTION…798
OPERATION…798
OPERATION…799
LIFT CHECK VALVE…800
FUNCTION…800
OPERATION…800
MAIN RELIEF VALVE…801
FUNCTION…801
OPERATION…801
2-STAGE SAFETY-SUCTION VALVE…802
FUNCTION…802
OPERATION…802
VARIABLE PRESSURE COMPENSATION VALVE…804
FUNCTION…804
ATTACHMENT CIRCUIT SELECTOR VALVE…806
FUNCTION…807
OPERATION…807
VALVE CONTROL…808
PPC VALVE…809
WORK EQUIPMENT AND SWING PPC VALVE…809
OPERATION…811
TRAVEL PPC VALVE…813
PRESSURE REDUCING VALVE…816
OPERATION…816
OPERATION…818
SERVICE PPC VALVE…822
PPC ACCUMULATOR…824
SOLENOID VALVE…825
OPERATION…826
RETURN OIL FILTER…827
FOR BREAKER…827
CENTER SWIVEL JOINT…828
TRAVEL MOTOR…829
TYPE: HMV160ADT-3…829
OPERATION OF MOTOR…832
PARKING BRAKE (PC300LC-7E0)…834
BRAKE VALVE OPERATION…836
FUNCTION…836
TRAVEL MOTOR…838
TYPE: KMV200ADT-2…838
OPERATION OF MOTOR…842
PARKING BRAKE (PC300HD-7E0)…844
BRAKE VALVE OPERATION…846
FUNCTION…846
SAFETY VALVE…848
FUNCTION…848
SWING MOTOR…851
TYPE: KMF230ABE-5…851
SPECIFICATIONS…851
SWING HOLDING BRAKE…854
OPERATION…854
OPERATION…854
RELIEF VALVE PORTION…855
OUTLINE…855
FUNCTION…855
OPERATION…855
REVERSE PREVENTION VALVE…856
EXPLANATORY DRAWING OF EFFECTS…857
FUNCTION…858
OPERATION…858
HYDRAULIC CYLINDERS…859
BOOM CYLINDER…859
ARM CYLINDER…859
BUCKET CYLINDER…860
WORK EQUIPMENT PIVOT POINT MEASUREMENTS…861
BOSS BUSHING/PINS…861
DIMENSION OF ARM…863
DIMENSION OF BUCKET…865
CAB AND ATTACHMENTS…867
AIR CONDITIONER PIPING…867
ELECTRICAL SYSTEM…868
ENGINE CONTROL…868
OUTLINE…868
OPERATION OF SYSTEM…869
ELECTRONIC COMPONENTS…870
FUEL CONTROL DIAL…870
FUNCTION…870
ENGINE CONTROLLER…871
COOLANT TEMPERATURE SENSOR…875
OIL PRESSURE SWITCH…875
ENGINE SPEED SENSOR…876
BOOST PRESSURE AND TEMPERATURE SENSOR…876
WIF (WATER-IN-FUEL DETECTION) SENSOR…877
ENGINE OIL LEVEL SENSOR…877
ELECTRONIC CONTROL SYSTEM…878
CONTROL FUNCTION…878
SYSTEM DIAGRAM…879
ENGINE AND PUMP CONTROL FUNCTION…881
PUMP AND VALVE CONTROL…885
LS CONTROL FUNCTION…886
CUT-OFF FUNCTION…886
2-STAGE RELIEF FUNCTION…886
POWER MAXIMIZING AND MACHINE PUSH-UP…887
AUTO-DECELERATION…889
OPERATION…889
AUTO-WARM-UP AND OVERHEAT PREVENTION…890
SWING CONTROL…892
TRAVEL CONTROL…894
ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR (IF EQUIPPED)…896
SYSTEM COMPONENTS…897
PPC OIL PRESSURE SWITCH…897
FUNCTION…897
OIL PRESSURE SENSOR…898
OPERATION…898
PUMP PRESSURE SENSOR (HIGH PRESSURE)…899
OPERATION…899
PUMP CONTROLLER…900
MONITOR SYSTEM…904
MACHINE MONITOR…905
OUTLINE…905
MONITOR CONTROL AND DISPLAY…908
MONITOR…908
DISPLAY…909
SWITCHES…913
BRIGHTNESS, CONTRAST ADJUSTMENT…921
SERVICE METER CHECK FUNCTION…922
DISPLAY LCD CHECK FUNCTION…922
USER CODE DISPLAY FUNCTION…923
SENSOR…925
HYDRAULIC OIL LEVEL SENSOR…925
HYDRAULIC OIL AND COOLANT TEMPERATURE SENSOR…925
FUEL LEVEL SENSOR…926
AIR CLEANER CLOGGING SENSOR…927
KOMTRAX TERMINAL SYSTEM…928
KOMTRAX TERMINAL…929
20 TESTING, ADJUSTING AND TROUBLESHOOTING…932
TESTING AND ADJUSTING…934
STANDARD VALUE TABLES…934
ENGINE RELATED…934
CHASSIS RELATED…935
SERVICE TOOLS…943
ENGINE SERVICE TOOLS…943
CHASSIS SERVICE TOOLS…944
ENGINE…945
AIR BOOST PRESSURE…945
AIR COMPRESSOR BELT TENSION…945
BLOW-BY PRESSURE…945
COMPRESSION PRESSURE…945
ENGINE OIL PRESSURE…945
ENGINE RPM…945
ENGINE SPEED…945
EXHAUST GAS COLOR…945
FUEL INJECTION TIMING…945
VALVE CLEARANCE…945
MEASURING ENGINE FUNCTIONS…946
MEASURE ENGINE SPEED WITH MACHINE MONITOR…946
PREPARATION…946
MEASURING LOW IDLE SPEED…946
MEASURING HIGH IDLE SPEED…946
MEASURING THE ENGINE SPEED WHEN 2-PUMPS ARE RELIEVED…946
MEASURING THE ENGINE SPEED AT 2-PUMP RELIEF AND POWER MAXIMIZING (NEAR RATED SPEED)…946
MEASURING THE SPEED WHEN AUTO-DECELERATION SPEED IS IN OPERATION…946
CYLINDER CUT-OUT OPERATION…947
NO INJECTION CRANKING OPERATION…947
CHECK AND ADJUST REFRIGERANT COMPRESSOR BELT…948
INSPECTION…948
ADJUSTMENT…948
MEASURING SWING CIRCLE BEARING CLEARANCE…949
CHECK AND ADJUST TRACK SHOE TENSION…950
INSPECTION…950
ADJUSTMENt…950
CHECK AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT…951
MEASURING…951
ADJUSTING…953
CHECKING CONTROL CIRCUIT OIL PRESSURE…956
MEASURING…956
CHECK AND ADJUST PUMP PC CONTROL CIRCUIT OIL PRESSURE…957
MEASURING…957
ADJUSTING…959
CHECK AND ADJUST PUMP LS CONTROL CIRCUIT OIL PRESSURE…960
MEASURING…960
ADJUSTING…964
MEASURING SOLENOID VALVE OUTPUT PRESSURE…965
MEASURING PPC VALVE OUTPUT PRESSURE…969
ADJUSTING PLAY IN WORK EQUIPMENT AND SWING PPC VALVES…970
TROUBLESHOOTING HYDRAULIC DRIFT IN WORK EQUIPMENT…971
INSPECTION OF BOOM AND BUCKET CYLINDERS…971
INSPECTION OF ARM CYLINDER…971
INSPECTION OF BOOM LOCK VALVE…972
INSPECTION OF PPC VALVE…972
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…973
MEASURING OIL LEAKAGE AMOUNT…973
BLEEDING AIR FROM VARIOUS SYSTEMS…976
DIODE INSPECTION PROCEDURES…978
SPECIAL FUNCTIONS OF MACHINE MONITOR…979
ORDINARY AND SPECIAL FUNCTIONS OF MACHINE MONITOR…980
OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE)…981
SERVICE MENU OPERATION AND DISPLAY…989
SWITCHING TO SERVICE MENU…989
MONITORING [01] FUNCTION…990
FUNCTION OF ABNORMALITY RECORD [02]…995
FUNCTION OF MAINTENANCE RECORD [03]…997
FUNCTION OF MAINTENANCE MODE CHANGE [04]…998
FUNCTION OF PHONE NUMBER ENTRY [05]…999
FUNCTION OF DEFAULT [06]…1000
FUNCTION OF ADJUSTMENT [07]…1002
FUNCTION OF CYLINDER CUT OUT OPERATION [08]…1003
FUNCTION OF NO INJECTION CRANKING [09]…1006
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…1008
PROCEDURE FOR TURNING ON KOMTRAX TERMINAL…1009
KOMTRAX TERMINAL LAMP INDICATIONS…1012
TROUBLESHOOTING ELECTRICAL SYSTEM…1015
PM-CLINIC INSPECTION TABLE…1018
TROUBLESHOOTING (GENERAL)…1024
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1025
SEQUENCE OF EVENTS IN TROUBLESHOOTING…1027
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…1028
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT…1028
HANDLING ELECTRONIC CONTROL UNIT…1033
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS…1034
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…1035
CHECKS BEFORE TROUBLESHOOTING…1037
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS…1038
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS…1039
TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS…1041
POSSIBLE PROBLEMS WHEN TROUBLESHOOTING A MODE…1043
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…1046
T-ADAPTER TABLE…1068
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…1072
CONNECTOR TYPES AND LOCATIONS…1077
CONNECTOR LAYOUT DRAWINGS…1083
TROUBLESHOOTING BY FAILURE CODE…1089
BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED…1092
LOCATION OF FUSE BOX AND FUSE NUMBERS…1093
INFORMATION CONTAINED IN TESTING PROCEDURES…1095
FAILURE CODE [A000N1]…1097
ENGINE OVER SPEED…1097
FAILURE CODE [AA10NX]…1098
AIR CLEANER CLOG SENSOR SYSTEM…1098
FAILURE CODE [AB00KE]…1100
CHARGE VOLTAGE IS LOW…1100
FAILURE CODE [B@BAZG]…1102
ENGINE OIL PRESSURE DROP…1102
FAILURE CODE [B@BAZK]…1104
ENGINE OIL LEVEL DROP…1104
FAILURE CODE [B@BCNS]…1106
COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)…1106
FAILURE CODE [B@BCZK]…1108
ENGINE COOLANT LEVEL DROP…1108
FAILURE CODE [B@HANS]…1110
HYDRAULIC OIL OVERHEAT CONDITION…1110
FAILURE CODE [CA111]…1112
CRITICAL INTERNAL FAILURE…1112
FAILURE CODE [CA115]…1113
ENGINE NE AND BACKUP SPEED SENSOR ERROR…1113
FAILURE CODE [CA122]…1114
CHARGE AIR PRESSURE SENSOR HIGH ERROR…1114
FAILURE CODE [CA123]…1116
CHARGE AIR PRESSURE SENSOR LOW ERROR…1116
FAILURE CODE [CA131]…1118
THROTTLE SENSOR HIGH ERROR…1118
FAILURE CODE [CA132]…1120
THROTTLE SENSOR LOW ERROR…1120
FAILURE CODE [CA144]…1122
COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)…1122
FAILURE CODE [CA145]…1124
COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (KX)…1124
FAILURE CODE [CA153]…1126
CHARGE AIR PRESSURE SENSOR HIGH ERROR…1126
FAILURE CODE [CA154]…1128
CHARGE AIR PRESSURE SENSOR LOW ERROR…1128
FAILURE CODE [CA187]…1130
SENSOR SUPPLY 2 VOLT LOW ERROR…1130
FAILURE CODE [CA221]…1132
AMBIENT PRESSURE SENSOR HIGH ERROR…1132
FAILURE CODE [CA222]…1134
AMBIENT PRESSURE SENSOR LOW ERROR…1134
FAILURE CODE [CA227]…1136
SENSOR SUPPLY 2 VOLT HIGH ERROR…1136
FAILURE CODE [CA234]…1138
ENGINE OVER SPEED…1138
FAILURE CODE [CA238]…1139
SPEED SENSOR SUPPLY VOLT ERROR…1139
FAILURE CODE [CA271]…1140
UMV/PCV1 SHORT ERROR…1140
FAILURE CODE [CA272]…1142
UMV/PCV1 OPEN ERROR…1142
FAILURE CODE [CA322]…1143
OPEN IN NO. 1 INJECTOR SOLENOID VALVE…1143
FAILURE CODE [CA323]…1145
OPEN IN NO. 5 INJECTOR SOLENOID VALVE…1145
FAILURE CODE [CA324]…1147
OPEN IN NO. 3 INJECTOR SOLENOID VALVE…1147
FAILURE CODE [CA325]…1149
OPEN IN NO. 6 INJECTOR SOLENOID VALVE…1149
FAILURE CODE [CA331]…1151
OPEN IN NO. 2 INJECTOR SOLENOID VALVE…1151
FAILURE CODE [CA332]…1153
OPEN IN NO. 4 INJECTOR SOLENOID VALVE…1153
FAILURE CODE [CA342]…1155
CALIBRATION CODE INCOMPATIBILITY…1155
FAILURE CODE [CA351]…1156
INJECTOR DRIVE CIRCUIT ERROR…1156
FAILURE CODE [CA352]…1158
AMBIENT PRESSURE SENSOR 1 VOLT LOW ERROR…1158
FAILURE CODE [CA386]…1160
AMBIENT PRESSURE SENSOR 1 VOLT HIGH ERROR…1160
FAILURE CODE [CA428]…1162
WATER IN FUEL SENSOR HIGH ERROR…1162
FAILURE CODE [CA429]…1164
WATER IN FUEL SENSOR LOW ERROR…1164
FAILURE CODE [CA441]…1166
BATTERY VOLTAGE LOW ERROR…1166
FAILURE CODE [CA442]…1168
BATTERY VOLTAGE HIGH ERROR…1168
FAILURE CODE [CA449]…1170
RAIL PRESSURE VERY HIGH…1170
FAILURE CODE [CA451]…1173
RAIL PRESSURE SENSOR HIGH ERROR…1173
FAILURE CODE [CA452]…1175
RAIL PRESSURE SENSOR LOW ERROR…1175
FAILURE CODE [CA553]…1177
RAIL PRESSURE ERROR…1177
FAILURE CODE [CA559]…1178
RAIL PRESSURE VERY LOW…1178
FAILURE CODE [CA689]…1180
ENGINE NE SPEED SENSOR ERROR…1180
FAILURE CODE [CA731]…1182
ENGINE BACK-UP SPEED SENSOR PHASE ERROR…1182
FAILURE CODE [CA757]…1183
PERSISTENT DATA LOSS ERROR…1183
FAILURE CODE [CA778]…1185
ENGINE BKUP SPEED SENSOR ERROR…1185
FAILURE CODE [CA1633]…1187
(KOMNET) DATALINK HAS TIME-OUT ERROR…1187
FAILURE CODE [CA2185]…1189
THROTTLE SENSOR HIGH ERROR…1189
FAILURE CODE [CA2186]…1191
THROTTLE SENSOR LOW ERROR…1191
FAILURE CODE [CA2249]…1193
RAIL PRESSURE VERY LOW…1193
FAILURE CODE [CA2265]…1195
ELECTRIC LIFT PUMP HIGH ERROR…1195
FAILURE CODE [CA2266]…1196
ELECTRIC LIFT PUMP LOW ERROR…1196
FAILURE CODE [CA2556]…1197
GRID HEATER RELAY VOLT LOW ERROR…1197
FAILURE CODE [CA2555]…1199
GRID HEATER RELAY VOLT HIGH ERROR…1199
FAILURE CODE [D110KB]…1201
BATTERY RELAY DRIVE S/C…1201
FAILURE CODE [D196KA]…1203
SERVICE RETURN RELAY ERROR…1203
FAILURE CODE [D196KB]…1205
SERVICE RETURN RELAY ERROR…1205
FAILURE CODE [DA25KP]…1207
SENSOR POWER ERROR…1207
FAILURE CODE [DA2RMC]…1209
PUMP COMMUNICATION ERROR…1209
FAILURE CODE [DA2SKQ]…1211
MODEL SELECTION ERROR…1211
FAILURE CODE [DAFRMC]…1213
MONITOR COMMUNICATION ERROR…1213
FAILURE CODE [DHPAMA]…1215
F PUMP PRESSURE SENSOR ERROR…1215
FAILURE CODE [DHPBMA]…1217
R PUMP PRESSURE SENSOR ERROR…1217
FAILURE CODE [DHS3MA]…1219
ARM CURL PRESSURE SENSOR ERROR…1219
FAILURE CODE [DHS4MA]…1221
CURL PPC PRESSURE SENSOR ERROR…1221
FAILURE CODE [DW43KA]…1223
TRAVEL SPEED SOLENOID ERROR…1223
FAILURE CODE [DW43KB]…1225
TRAVEL SPEED SOLENOID ERROR…1225
FAILURE CODE [DW45KA]…1227
SWING BRAKE SOLENOID ERROR…1227
FAILURE CODE [DW45KB]…1230
SWING BRAKE SOLENOID ERROR…1230
FAILURE CODE [DW91KA]…1233
TRAVEL JUNCTION SOLENOID ERROR…1233
FAILURE CODE [DW91KB]…1235
TRAVEL JUNCTION SOLENOID ERROR…1235
FAILURE CODE [DWJ0KA]…1237
MERGE-DIVIDER SOLENOID ERROR…1237
FAILURE CODE [DWJ0KB]…1239
MERGE-DIVIDER SOLENOID ERROR…1239
FAILURE CODE [DWK0KA]…1241
2-STAGE RELIEF SOLENOID ERROR…1241
FAILURE CODE [DWK0KB]…1243
2-STAGE RELIEF SOLENOID ERROR…1243
FAILURE CODE [DXA0KA]…1245
PC-EPC SOLENOID ERROR…1245
FAILURE CODE [DXA0KB]…1247
PC-EPC SOLENOID ERROR…1247
FAILURE CODE [DXE0KA]…1249
LS-EPC SOLENOID ERROR…1249
FAILURE CODE [DXE0KB]…1251
LS-EPC SOLENOID ERROR…1251
FAILURE CODE [DXE4KA]…1253
SERVICE CURRENT EPC ERROR…1253
FAILURE CODE [DXE4KB]…1255
SERVICE CURRENT EPC ERROR…1255
FAILURE CODE [DY20KA]…1257
WINDSHIELD WIPER MOTOR DRIVE ERROR…1257
FAILURE CODE [DY20MA]…1259
WINDSHIELD WIPER MOTOR DRIVE ERROR…1259
FAILURE CODE [DY2CKB]…1261
WINDSHIELD WASHER DRIVE ERROR…1261
FAILURE CODE [DY2DKB]…1263
WINDSHIELD WIPER DRIVE ERROR…1263
FAILURE CODE [DY2EKB]…1265
WINDSHIELD WIPER DRIVE ERROR…1265
[E-1]…1267
ENGINE WILL NOT CRANK…1267
[E-2]…1269
AUTO DECELERATOR DOES NOT WORK…1269
[E-3]…1270
AUTO ENGINE WARM UP DEVICE DOES NOT WORK…1270
[E-4]…1271
COLD START PRE-HEATER DOES NOT WORK…1271
[E-5]…1273
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE…1273
[E-6]…1275
POWER MAXIMIZING FUNCTION DOES NOT OPERATE…1275
[E-7]…1277
MACHINE MONITOR DOES NOT OPERATE…1277
[E-8]…1279
MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS…1279
[E-9]…1280
MACHINE MONITOR DOES NOT DISPLAY ITEMS CORRECTLY…1280
[E-10]…1281
MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING…1281
[E-11]…1282
COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT…1282
[E-12]…1284
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY…1284
[E-13]…1286
MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING…1286
[E-17]…1287
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY…1287
[E-15]…1289
WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS…1289
[E-16]…1291
WINDSHIELD WIPER AND WASHER DO NOT OPERATE…1291
WINDSHIELD WASHER DRIVE ERROR…1293
[E-17]…1295
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE…1295
[E-18]…1297
BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR…1297
[E-19]…1299
BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR…1299
[E-20]…1301
ARM IN NOT CORRECTLY DISPLAYED ON MONITOR…1301
[E-21]…1303
ARM OUT NOT CORRECTLY DISPLAYED ON MONITOR…1303
[E-22]…1305
BUCKET CURL CORRECTLY DISPLAYED ON MONITOR…1305
[E-23]…1307
BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR…1307
[E-24]…1309
SWING NOT CORRECTLY DISPLAYED ON MONITOR…1309
[E-25]…1311
TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR…1311
[E-26]…1313
TRAVEL DIFFERENTIAL NOT CORRECTLY DISPLAYED ON MONITOR…1313
[E-27]…1315
SERVICE NOT CORRECTLY DISPLAYED ON MONITOR…1315
[E-28]…1317
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…1317
[E-29]…1319
AIR CONDITIONER SYSTEM DOES NOT WORK…1319
[E-30]…1321
TRAVEL ALARM DOES NOT SOUND…1321
[E-31]…1323
HORN DOES NOT SOUND…1323
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…1328
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SY…1330
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…1332
[H-1]…1333
WORK EQUIPMENT, TRAVEL AND SWING SPEEDS ARE SLOW…1333
[H-2]…1334
ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS…1334
[H-3]…1335
NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT…1335
[H-4]…1335
ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP…1335
[H-5]…1336
AUTO-DECELERATOR DOES NOT WORK…1336
[H-6]…1336
FINE CONTROL MODE DOES NOT FUNCTION…1336
[H-7]…1337
BOOM MOVES SLOWLY OR LACKS POWER…1337
[H-8]…1338
WORK EQUIPMENT MOVES SLOWLY OR LACKS POWER…1338
[H-9]…1339
BUCKET MOVES SLOWLY OR LACKS POWER…1339
[H-10]…1339
WORK EQUIPMENT DOES NOT MOVE IN A INDEPENDENT OPERATION…1339
[H-11]…1340
WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT…1340
[H-12]…1341
WORK EQUIPMENT HAS EXCESSIVE LAG TIM…1341
[H-13]…1341
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT…1341
[H-14]…1342
ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE…1342
[H-15]…1342
IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY…1342
[H-16]…1342
IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY…1342
[H-17]…1343
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY…1343
[H-18]…1344
MACHINE SWERVES WHEN TRAVELING…1344
[H-19]…1345
MACHINE TRAVELS SLOWLY…1345
[H-20]…1346
MACHINE CANNOT BE STEERED EASILY OR LACKS POWER…1346
[H-21]…1347
TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING…1347
[H-22]…1347
TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY)…1347
[H-23]…1348
MACHINE DOES NOT SWING…1348
[H-24]…1349
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW…1349
[H-25]…1350
EXCESSIVE OVERRUN WHEN STOPPING SWING…1350
[H-26]…1351
THERE IS A SUDDEN SHOCK WHEN STOPPING SWING…1351
[H-27]…1351
ABNORMAL NOISE CAUSED WHEN STOPPING SWING…1351
30 DISASSEMBLY AND ASSEMBLY…1353
METHOD OF USING MANUAL…1357
COATING MATERIALS LIST…1358
SPECIAL TOOLS LIST…1362
SKETCHES OF SPECIAL TOOLS…1366
PRECAUTIONS DURING OPERATION…1368
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK…1368
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK…1369
PRECAUTIONS WHEN COMPLETING THE OPERATIONS…1370
OTHER PRECAUTIONS…1370
ENGINE…1371
CONNECTOR REPAIR PROCEDURES…1372
CONTACT TERMINAL REMOVAL (HD30 TYPE)…1372
STRIPPING INSULATION…1373
CRIMPING CONTACT TERMINAL (HD30 TYPE)…1374
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…1375
CONTACT TERMINAL REMOVAL (DT TYPE)…1376
STRIPPING INSULATION…1377
CRIMPING CONTACT TERMINAL (DT TYPE)…1378
INSERTION OF CONTACT TERMINAL (DT TYPE)…1379
ENGINE AND COOLING SYSTEM…1380
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…1380
SPECIAL TOOLS…1380
REMOVAL…1380
INSTALLATION…1382
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…1385
SPECIAL TOOLS…1385
REMOVAL…1385
INSTALLATION…1387
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…1389
SPECIAL TOOLS…1389
REMOVAL…1389
INSTALLATION…1391
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…1396
SPECIAL TOOLS…1396
REMOVAL…1396
INSTALLATION…1403
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…1411
REMOVAL…1411
INSTALLATION…1412
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY…1413
REMOVAL…1413
INSTALLATION…1415
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY…1416
REMOVAL…1416
INSTALLATION…1416
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY…1417
SPECIAL TOOLS…1417
REMOVAL…1417
INSTALLATION…1422
POWER TRAIN…1423
REMOVAL AND INSTALLATION OF FINALDRIVE ASSEMBLY…1423
REMOVAL…1423
INSTALLATION…1424
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE…1425
SPECIAL TOOLS…1425
DISASSEMBLY…1425
ASSEMBLY…1430
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…1436
REMOVAL…1436
INSTALLATION…1437
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…1438
SPECIAL TOOLS…1438
DISASSEMBLY…1438
ASSEMBLY…1441
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…1448
REMOVAL…1448
INSTALLATION…1448
UNDERCARRIAGE AND FRAME…1449
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…1449
SPECIAL TOOLS…1449
ASSEMBLY…1449
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…1451
SPECIAL TOOLS…1451
ASSEMBLY…1451
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…1453
SPECIAL TOOLS…1453
DISASSEMBLY…1453
ASSEMBLY…1454
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY…1457
SPECIAL TOOLS…1457
DISASSEMBLY…1457
ASSEMBLY…1459
REMOVAL AND INSTALLATION OF SPROCKET…1461
REMOVAL…1461
INSTALLATION…1461
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY…1462
SPECIAL TOOLS…1462
EXPANSION OF TRACK SHOE…1462
INSTALLATION OF TRACK SHOE…1463
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…1465
REMOVAL…1465
INSTALLATION…1467
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY…1468
REMOVAL…1468
INSTALLATION…1468
HYDRAULIC SYSTEM…1469
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…1469
REMOVAL…1469
INSTALLATION…1470
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…1471
SPECIAL TOOLS…1471
DISASSEMBLY…1471
ASSEMBLY…1472
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY…1473
REMOVAL…1473
INSTALLATION…1475
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY…1476
REMOVAL…1476
INSTALLATION…1479
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…1480
SPECIAL TOOLS…1480
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY…1483
SPECIAL TOOLS…1483
REMOVAL…1483
INSTALLATION…1486
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT…1487
REMOVAL…1487
INSTALLATION…1487
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY…1488
DISASSEMBLY…1488
ASSEMBLY…1488
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY…1490
DISASSEMBLY…1490
ASSEMBLY…1490
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…1491
SPECIAL TOOLS…1491
DISASSEMBLY…1491
ASSEMBLY…1494
WORK EQUIPMENT…1498
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…1498
SPECIAL TOOLS…1498
REMOVAL…1498
INSTALLATION…1500
CAB AND ITS ATTACHMENTS…1502
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY…1502
REMOVAL…1502
INSTALLATION…1504
REMOVAL AND INSTALLATION OF OPERATOR’S CAB FIXED WINDOW…1505
SPECIAL TOOLS…1506
REMOVAL…1506
INSTALLATION…1507
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY…1518
REMOVAL…1518
INSTALLATION…1521
ELECTRICAL SYSTEM…1526
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…1526
SPECIAL TOOLS…1526
REMOVAL…1526
INSTALLATION…1529
REMOVAL AND INSTALLATION OFMACHINE MONITOR…1530
REMOVAL…1530
INSTALLATION…1530
REMOVAL AND INSTALLATION OF PUMP CONTROLLER…1531
REMOVAL…1531
INSTALLATION…1531
REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL…1532
REMOVAL…1532
INSTALLATION…1532
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER…1533
REMOVAL…1533
INSTALLATION…1533
90 OTHERS…1535
HYDRAULIC CIRCUIT DIAGRAMS…1537
(VIEW “A”) 1 OF 5…1537
(VIEW “A”) 2 OF 5…1539
(VIEW “A”) 3 OF 5…1541
(VIEW “A”) 4 OF 5…1543
(VIEW “A”) 5 OF 5…1545
(VIEW “B”) 1 OF 6…1547
(VIEW “B”) 2 OF 6…1549
(VIEW “B”) 3 OF 6…1551
(VIEW “B”) 4 OF 6…1553
(VIEW “B”) 5 OF 6…1555
(VIEW “B”) 6 OF 6…1557
ELECTRICAL CIRCUIT DIAGRAMS…1559
TO CABIN HARNESS…1559
CABIN HARNESS VIEW 1…1561
CABIN HARNESS VIEW 2…1563
CONTROLLER (CR700) VIEW…1565
FLOOR HARNESS VIEW…1567
MONITOR AND RADIO HARNESS VIEW…1569
LEFT CONSOLE, FUSE PANEL AND KOMTRAX CONTROLLER…1571
WARNING AND INDICATOR LAMPS…1573
ENGINE AND DRIVE SYSTEM SENSORS AND CONTROLLERS…1575
ENGINE SENSORS AND CONTROLLERS (PC300LC-7E0)…1577
FUEL INJECTOR SYSTEM VIEW (PC300LC-7E0)…1579
ENGINE SENSORS AND CONTROLLERS (PC300HD-7E0)…1581
FUEL INJECTOR SYSTEM VIEW (PC300HD-7E0)…1583
Komatsu Logging/Road Builder Excavator Excavator GALEO PC300LC-7E0, PC300HD-7E0, PC300LL-7E0 Repair Service Manuals