Complete service repair manual with Electrical Wiring Diagrams for Komatsu PC300LC-6, PC300HD-6 Hydraulic Excavator, Logging Excavator PC300LL-6 avance, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu PC300LC-6, PC300HD-6 Hydraulic Excavator, Logging Excavator PC300LL-6 avance 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.
CEBM002901 – Hydraulic Excavator PC300LC-6, PC300HD-6 Shop Manual.pdf
CEBM3006C2 – Hydraulic Excavator PC300LC-6, PC300HD-6 Shop Manual.pdf
CEBM009500 – Logging Excavator PC300LL-6 avance Shop Manual.pdf
CEBM018703 – Hydraulic Excavator PC300LC-8, PC300HD-8 Shop Manual.pdf
CEAM008500 – Logging Excavator PC300LL-6 avance Operation & Maintenance Manual.pdf
CEAM207040 – Hydraulic Excavator PC300LC-5 with KDC 614TA Engine Operation & Maintenance Manual.pdf
SEAM02070501 – Hydraulic Excavator PC300-5, PC300LC-5 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,445 pages
File Format: PDF
Language: English
CEAM008500 – Logging Excavator PC300LL-6 avance Operation & Maintenance Manual…2
COVER…2
INTRODUCTION…8
FOREWORD…9
SAFETY INFORMATION…9
INTRODUCTION…10
INTENDED USE…10
FEATURES…10
BREAKING IN THE MACHINE…10
LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR…11
P.I.N. PLATE LOCATION…11
ENGINE SERIAL NO. PLATE LOCATION…11
TABLE TO ENTER NUMBERS AND DISTRIBUTOR…11
TABLE OF CONTENTS…12
SAFETY…20
WARNING LABELS…21
GENERAL PRECAUTIONS…28
SAFETY RULES…28
SAFETY FEATURES…28
UNAUTHORIZED MODIFICATION…28
INSIDE OPERATOR’S COMPARTMENT…29
CLOTHING AND PERSONAL PROTECTIVE ITEMS…29
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT…29
MOUNTING AND DISMOUNTING…30
INJURY FROM WORK EQUIPMENT…30
FIRE PREVENTION FOR FUEL AND OIL…30
PRECAUTIONS AT HIGH TEMPERATURES…31
ASBESTOS DUST HAZARD PREVENTION…31
FIRE EXTINGUISHER AND FIRST AID KIT…31
CAB GLASS…32
WINDOW WASHER FLUID…32
ESCAPE FROM FIRE…32
PROTECTION AGAINST FALLING OR FLYING OBJECTS…32
MACHINES WITH ACCUMULATOR…33
PRECAUTIONS FOR ATTACHMENTS…33
INDOOR VENTILATION…33
EMERGENCY EXIT FROM OPERATORS CAB…33
PRECAUTIONS DURING OPERATION…34
BEFORE STARTING ENGINE…34
SAFETY AT WORK SITE…34
FIRE PREVENTION…34
VENTILATION FOR ENCLOSED AREAS…34
IN OPERATOR’S CAB…34
PRECAUTIONS FOR MIRROR AND LIGHTS…35
WHEN STARTING ENGINE…35
OPERATING MACHINE…36
WHEN STARTING ENGINE…36
CHECK DIRECTION BEFORE STARTING MACHINE…36
CHECK THAT NO ONE IS IN AREA BEFORE SWINGING OR TRAVELING IN REVERSE…36
NEVER LET ANYONE RIDE ON ATTACHMENT…36
PRECAUTIONS WHEN TRAVELING…37
OPERATE CAREFULLY ON SNOW…37
TRAVELING ON SLOPES…38
PROHIBITED OPERATIONS…38
PRECAUTIONS FOR OPERATION…39
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…39
WORKING ON LOOSE GROUND…40
OPERATING ON SLOPES…40
PARKING THE MACHINE…40
PRECAUTIONS IN COLD WEATHER…41
TRANSPORTATION…42
LOADING AND UNLOADING…42
PRECAUTIONS WHEN LIFTING…42
SHIPPING…43
BATTERY…44
BATTERY HAZARD PREVENTION…44
STARTING WITH BOOSTER CABLES…44
CHARGING BATTERY…45
TOWING…46
PRECAUTIONS WHEN TOWING…46
PRECAUTIONS FOR MAINTENANCE…47
BEFORE CARRYING OUT MAINTENANCE…47
CONTACT WHEN THERE IS FAILURE…47
WARNING TAG…47
CLEAN BEFORE INSPECTION OR MAINTENANCE…47
NEAT CLEAN WORK PLACE…47
FOLLOW LEADER IN OPERATIONS WITH OTHER WORKERS…47
RADIATOR COOLANT LEVEL…48
PROPER TOOLS…48
STOP ENGINE PRIOR TO INSPECTION AND MAINTENANCE…48
SUPPORT FOR WORK EQUIPMENT…48
PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS…49
USE OF LIGHTING…49
FIRE PREVENTION…49
RULES TO FOLLOW WHEN ADDING FUEL OR OIL…49
DURING MAINTENANCE…50
PERSONNEL…50
REMOVAL, INSTALLATION AND STORAGE OF ATTACHMENTS…50
WORK UNDER THE MACHINE…50
NOISE…50
WHEN WORKING ON MACHINE…50
LOCK INSPECTION COVERS…50
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…51
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE…51
FLYING PIECES WITH HAMMER WORK…51
KEEP THE MACHINE CLEAN…51
WELDING REPAIRS…52
REMOVE BATTERY TERMINALS…52
ACTION WHEN ABNORMALITY IS FOUND DURING INSPECTION…52
RULES TO FOLLOW WHEN ADDING FUEL…52
PRECAUTIONS WHEN ADJUSTING TRACK TENSION…52
HANDLING HIGH PRESSURE HOSES…53
PRECAUTIONS WITH HIGH PRESSURE OIL…53
PRECAUTIONS AT HIGH TEMPERATURE OR PRESSURE…53
WASTE MATERIALS…54
CHECKS AFTER INSPECTION AND MAINTENANCE…54
MAINTENANCE FOR AIR CONDITIONER…54
OPERATION…56
GENERAL…57
VIEW OF MACHINE…57
GENERAL VIEW OF OPERATORS COMPARTMENT…58
GENERAL VIEW OF MONITOR PANEL…59
EXPLANATION OF COMPONENTS…60
MACHINE MONITOR…60
MONITOR LIGHT GROUP…62
METER DISPLAY PORTION…64
SWITCHES…68
SWITCHES…71
CONTROL LEVERS AND PEDALS…76
OPERATOR’S SEAT AND SEAT BELT…79
SEAT ADJUSTMENT…79
SEAT BELT…80
MONITOR PANEL…81
ADJUSTMENT ANGLE…81
ROOF VENT…81
WHEN OPENING…81
WHEN CLOSING…81
FRONT WINDOW…82
WHEN OPENING…82
WHEN CLOSING…83
FRONT BOTTOM WINDOW…84
DOOR LOCK…84
CAP, COVER WITH LOCK…85
METHOD OF OPENING AND CLOSING LOCK CAP…85
METHOD OF OPENING AND CLOSING COVER LOCK…85
OPERATOR EASE…86
HOT AND COOL BOX…86
STORAGE BOX…86
ASHTRAY…86
AIR CONDITIONER…87
GENERAL LOCATIONS ON CONTROL PANEL…87
PRECAUTIONS WHEN USING AIR CONDITIONER…89
CHECK, MAINTAIN MACHINE WITH AIR CONDITIONER…89
AM/FM RADIO…90
EXPLANATION OF COMPONENTS…90
METHOD OF OPERATION…92
PRECAUTIONS WHEN USING…94
SPECIFICATIONS…94
ELECTRIC POWER TAKE OUT ADAPTER…94
FUSE…95
FUSIBLE LINK…96
CONTROLLERS…96
TOOL BOX…96
GREASE GUN HOLDER…96
HANDLING ACCUMULATOR…97
OPERATION…98
CHECK BEFORE STARTING ENGINE…98
WALK AROUND CHECK…98
CHECK BEFORE STARTING…100
ADJUST OPERATOR’S SEAT…103
ADJUST SEAT BELT…103
ADJUST ARM RESTS…103
ADJUST MONITOR PANEL…103
OPERATIONS AND CHECKS BEFORE STARTING ENGINE…104
STARTING ENGINE…106
NORMAL STARTING…106
STARTING IN COLD WEATHER…107
OPERATIONS AND CHECKS AFTER STARTING ENGINE…109
WHEN NORMAL…109
AUTOMATIC WARM UP OPERATION…112
MOVING MACHINE…115
MOVING MACHINE FORWARD…115
MOVING MACHINE REARWARD…117
STEERING MACHINE…119
STEERING (CHANGING DIRECTION)…119
STOPPING MACHINE…120
SWINGING…121
OPERATION OF WORK EQUIPMENT…122
ACTIVE MODE…123
WORKING MODES…124
WORKING MODE…124
POWER MAX, SWIFT SLOW DOWN…124
PRECAUTIONS FOR OPERATION…126
PRECAUTIONS WHEN TRAVELING…126
PRECAUTIONS AT HI SPEED TRAVEL…126
PERMISSIBLE WATER DEPTH…126
PRECAUTIONS WHEN TRAVELING ON HILLS…127
BRAKING WHEN TRAVELING DOWNHILL…127
IF SHOES SLIP…127
IF ENGINE STOPS…127
PRECAUTIONS ON SLOPES…127
HOW TO ESCAPE FROM MUD…128
WHEN ONE SIDE IS STUCK…128
WHEN BOTH SIDES ARE STUCK…128
PARKING MACHINE…129
CHECK AFTER FINISHING WORK…131
STOPPING ENGINE…131
CHECK AFTER STOPPING ENGINE…131
LOCKING…132
TRANSPORTATION…133
TRANSPORTATION PROCEDURE…133
LOADING, UNLOADING WORK ON TRAILERS…133
LOADING…134
SECURING MACHINE…135
UNLOADING…137
TRACK FRAME GAUGE…140
REDUCING TRACK GAUGE…140
INCREASING TRACK GAUGE…140
COLD WEATHER OPERATION…142
PRECAUTIONS FOR LOW TEMPERATURE…142
FUEL AND LUBRICANTS…142
COOLANT…142
BATTERY…143
PRECAUTIONS AFTER COMPLETION OF WORK…144
AFTER COLD WEATHER…144
LONG TERM STORAGE…145
BEFORE STORAGE…145
DURING STORAGE…145
AFTER STORAGE…145
MACHINE START AFTER LONG TERM STORAGE…146
TROUBLESHOOTING…147
PHENOMENA THAT ARE NOT FAILURES…147
METHOD OF TOWING DISABLED MACHINE…147
USING MACHINE FOR LIGHT WEIGHT TOWING…147
PRECAUTIONS ON PARTICULAR JOB SITES…147
DISCHARGED BATTERY…148
REMOVING AND INSTALLING BATTERY…148
PRECAUTIONS FOR CHARGING BATTERY…148
STARTING ENGINE WITH BOOSTER CABLE…149
OTHER TROUBLE…151
ELECTRICAL SYSTEM…151
CHASSIS…152
ENGINE…153
ELECTRONIC CONTROL SYSTEM…154
MAINTENANCE…156
GUIDES TO MAINTENANCE…157
OUTLINES OF SERVICE…159
OUTLINE OF OIL, FUEL, COOLANT…159
OIL…159
FUEL…159
COOLANT…160
GREASE…160
STORING OIL AND FUEL…160
FILTERS…160
RELATING TO ELECTRICAL SYSTEM…160
OUTLINE OF HYDRAULIC SYSTEM…161
WEAR PARTS LIST…162
USE OF FUEL, COOLANT AND LUBRICANTS…163
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…163
ABBREVIATIONS…163
ENGINE OIL SPECIFICATIONS…164
NORMAL OPERATION…164
ARCTIC OPERATION…164
DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYD…165
FINAL DRIVE OIL SPECIFICATIONS…165
FUEL SYSTEM…165
COOLING SYSTEM…166
GENERAL…166
WATER…166
ANTIFREEZE…166
INHIBITORS/CONDITIONERS…167
STANDARD TIGHTENING TORQUES…171
INTRODUCTION OF NECESSARY TOOLS…171
BOLT IDENTIFICATION CHART…172
PERIODIC REPLACEMENT OF CRITICAL PARTS…173
MAINTENANCE SCHEDULE CHART…174
SERVICE PROCEDURE…176
INITIAL 250 HOURS SERVICE…176
FUEL FILTER CARTRIDGE…176
WHEN REQUIRED…177
CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT…177
DRAIN, FLUSH AND REFILL COOLING SYSTEM…179
CHECK AND TIGHTEN TRACK SHOE BOLTS…184
CHECK AND ADJUST TRACK TENSION…184
CHECK ELECTRICAL INTAKE AIR HEATER…186
CHECK WINDOW WASHER FLUID, ADD FLUID…186
CHECK, MAINTAIN AIR CONDITIONER…187
CLEAN IN LINE FILTERS…188
CHECK BEFORE STARTING…189
CHECK COOLANT LEVEL, ADD COOLANT…189
CHECK ENGINE OIL LEVEL, ADD OIL…189
CHECK FUEL LEVEL, ADD FUEL…190
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…190
CHECK AIR CLEANER FOR CLOGGING…191
CHECK ELECTRIC WIRING…191
CHECK FUNCTION OF HORN…192
DRAIN WATER FROM THE FUEL WATER SEPARATOR…192
EVERY 50 HOURS SERVICE…193
GREASE LUBRICATION…193
DRAIN WATER AND SEDIMENT FROM FUEL TANK…193
EVERY 100 HOURS SERVICE…194
PREVIOUS MAINTENANCE…194
GREASE LUBRICATION…194
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…194
EVERY 250 HOURS SERVICE…195
PREVIOUS MAINTENANCE…195
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…195
CHECK LEVEL OF BATTERY ELECTROLYTE…195
LUBRICATE SWING CIRCLE (3 POINTS)…196
CHECK BELT TENSION, ADJUST…196
AIR CONDITIONER COMPRESSOR BELT TENSION…198
EVERY 500 HOURS SERVICE…199
PREVIOUS MAINTENANCE…199
REPLACE FUEL FILTER CARTRIDGE…199
REPLACE IN LINE FUEL STRAINER…200
CHECK SWING PINION GREASE LEVEL, ADD GREASE…200
CLEAN AND INSPECT RADIATOR AND OIL COOLER…201
CLEAN AIR CONDITIONER FILTERS…201
REPLACE HYDRAULIC TANK BREATHER…202
CHANGE ENGINE OIL, REPLACE FILTER CARTRIDGE…202
REPLACE HYDRAULIC FILTER ELEMENT…204
CORROSION RESISTOR…205
EVERY 1000 HOURS SERVICE…206
PREVIOUS MAINTENANCE…206
CHANGE OIL IN SWING MACHINERY CASE…206
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…206
CHECK TIGHTENING PARTS OF TURBOCHARGER…207
CHECK PLAY OF TURBOCHARGER ROTOR…207
CHECK DRIVE BELT, TENSIONER BEARING AND FAN HUB…207
EVERY 2000 HOURS SERVICE…209
PREVIOUS MAINTENANCE…209
CHANGE OIL IN FINAL DRIVE CASE…209
CLEAN HYDRAULIC TANK STRAINER…209
CLEAN, CHECK TURBOCHARGER…210
CHECK ALTERNATOR, STARTING MOTOR…210
CHECK VIBRATION DAMPER…210
CHECK ENGINE VALVE CLEARANCE, ADJUST…211
EVERY 4000 HOURS SERVICE…215
PREVIOUS MAINTENANCE…215
CHECK WATER PUMP…215
EVERY 5000 HOURS SERVICE…216
PREVIOUS MAINTENANCE…216
CHANGE OIL IN HYDRAULIC TANK…216
PROCEDURE FOR BLEEDING AIR…217
SPECIFICATIONS…220
SPECIFICATIONS AND DIMENSIONS…221
SPECIFICATIONS…221
DIMENSIONS…221
OPTIONS, ATTACHMENTS…224
GENERAL PRECAUTIONS…225
PRECAUTIONS RELATED TO SAFETY…225
SELECTION OF TRACK SHOES…226
CEAM207040 – Hydraulic Excavator PC300LC-5 with KDC 614TA Engine Operation & Maintenance Manual…230
COVER PAGE…230
1. FORWARD …234
2. SAFETY INFORMATION …235
3. INTRODUCTION …236
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…237
5. CONTENTS …238
SAFETY…242
6. GENERAL PRECAUTIONS …243
7. PRECAUTIONS DURING OPERATION…249
7.1 BEFORE STARTING ENGINE…249
7.2 OPERATING MACHINE…251
7.3 TRANSPORTATION…257
7.4 BATTERY…258
7.5 TOWING…259
7.6 BUCKET WITH HOOK…260
8. PRECAUTIONS FOR MAINTENANCE …262
8.1 BEFORE CARRYING OUT MAINTENANCE…262
8.2 DURING MAINTENANCE…265
9. POSITION FOR ATTACHING SAFETY LABELS…269
OPERATION…274
10. GENERAL VIEW…275
10.1 GENERAL VIEW OF MACHINE…275
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…276
11. EXPLANATION OF COMPONENTS…277
11.1 ELECTRONIC MONITOR AND CONTROL CONSOLE (EMACC)…277
11.2 METER…286
11.3 SWITCHES…287
11.4 CONTROL LEVERS, PEDALS…293
11.5 CEILING WINDOW…297
11.6 WINDSHIELD…297
11.7 DOOR HOLD OPEN LOCK…299
11.8 CAP, COVER WITH LOCK…299
11.9 DEFROSTER CONTROL…300
11.10 STORAGE TRAY…300
11.11 ASHTRAY…300
11.12 FUSE…301
11.13 FUSIBLE LINK…301
11.14 HANDLING ACCUMULATOR…302
12. OPERATION…303
12.1 CHECK BEFORE STARTING…303
12.2 STARTING ENGINE…317
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…320
12.4 MOVING MACHINE OFF…323
12.5 STEERING THE MACHINE…324
12.6 STOPPING THE MACHINE…325
12.7 SWINGING…326
12.8 OPERATION OF WORK EQUIPMENT…327
12.9 WORKING MODE SELECTION…329
12.10 PROHIBITIONS FOR OPERATION…331
12.11 PRECAUTIONS FOR OPERATION…334
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…335
12.13 HOW TO ESCAPE FROM MUD…336
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…337
12.15 REPLACEMENT AND INVERSION OF BUCKET…339
12.16 PARKING MACHINE…340
12.17 CHECK AFTER FINISHING WORK…341
12.18 STOPPING ENGINE…341
12.19 CHECK AFTER STOPPING ENGINE…342
12.20 LOCKING AND SECURING MACHINE…343
13. TRANSPORTATION…344
13.1 LOADING AND UNLOADING MACHINE…344
13.2 TRANSPORTING MACHINE…345
13.3 PRECAUTIONS FOR TRANSPORTATION…346
13.4 DISASSEMBLING MACHINE FOR TRANSPORT…346
14. COLD WEATHER OPERATION…349
14.1 PRECAUTIONS FOR LOW TEMPERATURE…349
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…350
14.3 AFTER COLD WEATHER…350
15. LONG-TERM STORAGE…351
15.1 BEFORE STORAGE…351
15.2 DURING STORAGE…353
15.3 AFTER STORAGE…354
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…354
16. TROUBLESHOOTING…355
16.1 MOVING A DISABLED MACHINE…355
16.2 PRECAUTIONS ON PARTICULAR JOBSITES…356
16.3 IF BATTERY IS DISCHARGED…357
16.4 STARTING ENGINE WITH BOOSTER CABLE…357
16.5 OTHER TROUBLE…359
16.6 PHENOMENA THAT ARE NOT FAILURES…363
MAINTENANCE…364
17. GUIDES TO MAINTENANCE…365
18. OUTLINES OF SERVICE…368
18.1 OUTLINE OF OIL, FUEL, COOLANT…368
18.2 OUTLINE OF ELECTRICAL SYSTEM…371
18.3 OUTLINE OF HYDRAULIC SYSTEM…372
19. WEAR PARTS LIST…373
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…375
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…375
20.2 ENGINE OIL SPECIFICATIONS…376
20.3 GREASE SPECIFICATIONS…376
20.4 DIESEL FUEL SPECIFICATIONS…377
20.5 COOLANT SPECIFICATIONS…377
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…382
21.1 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS…382
21.2 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…382
21.3 TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS…383
21.4 UNIT CONVERSIONS…384
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…390
23. MAINTENANCE SCHEDULE CHART…391
24. SERVICE PROCEDURE…394
24.1 SEASONAL PREPARATIONS…394
24.2 AIR CLEANING SYSTEM…395
24.3 AIR CONDITIONER…399
24.4 BELTS…400
24.5 BUCKET…403
24.6 COOLING SYSTEM…409
24.7 ELECTRICAL SYSTEM…415
24.8 ENGINE…418
24.9 ETHER INJECTOR (IF EQUIPPED)…425
24.10 FINAL DRIVE…427
24.11 FUEL SYSTEM…428
24.12 HYDRAULIC SYSTEM…434
24.13 LUBRICATION FITTINGS…447
24.14 PTO CASE…449
24.15 SEAT BELT…449
24.16 SWING MACHINERY…450
24.17 TRACKS…453
24.18 TURBOCHARGER…455
24.19 WALK AROUND INSPECTION…457
24.20 WINDOW WASHER…457
SPECIFICATIONS…458
25. SPECIFICATIONS…459
OPTIONS & ATTACHMENTS…462
26. GENERAL PRECAUTIONS…463
26.1 PRECAUTIONS RELATED TO SAFETY…463
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…464
27. HANDLING BUCKET WITH HOOK…465
27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK…465
27.2 PROHIBITED OPERATIONS…465
27.3 PRECAUTIONS DURING OPERATIONS…465
28. OPERATING AIR CONDITIONER…466
28.1 CONTROL PANEL…466
28.2 COOLING…467
28.3 HEATING…468
28.4 DEHUMIDIFY AND HEATING…469
29. RADIO…470
29.1 OPERATION…470
29.2 CARE AND MAINTENANCE…470
29.3 TROUBLESHOOTING…470
30. OPTIONAL ELECTRICAL EQUIPMENT…471
30.1 INSTALLATION OF OPTIONAL ELECTRICAL EQUIPMENT…471
30.2 INSTALLATION OF ADDITIONAL LAMPS…472
31. INTRODUCTION OF ATTACHMENTS…473
31.1 BUCKET SELECTION…473
31.2 BUCKET TEETH SELECTION…473
31.3 BUCKET INSTALLATION COMBINATIONS…474
31.4 SELECTION OF TRACK SHOES…475
31.5 USING THE EXTENSION ARM…476
31.6 HANDLING THE CLAMSHELL BUCKET…476
32. EXTENDING MACHINE SERVICE LIFE…477
32.1 HYDRAULIC BREAKER…477
32.2 CRUSHER…480
32.3 GRAPPLE…481
32.4 BUCKET WITH THUMB GRAPPLE…482
32.5 ROTATING GRAPPLE…483
32.6 SHEAR…484
32.7 HYDRAULIC PILE DRIVER…485
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE…486
CEBM002901 – Hydraulic Excavator PC300LC-6, PC300HD-6 Shop Manual…489
COVER…489
CONTENTS…490
00 FORWARD…497
SAFETY…498
GENERAL…500
HOW TO READ THE SHOP MANUAL…501
HOISTING INSTRUCTIONS…502
COATING MATERIALS…503
STANDARD TIGHTENING TORQUE…505
ELECTRIC WIRE CODE…509
CONVERSION TABLES…510
METHOD OF USING THE CONVERSION TABLE…510
01 GENERAL…516
SPECIFICATION DRAWINGS…517
SPECIFICATIONS…521
WEIGHT TABLE…523
FUEL COLLANT AND LUBRICANTS…525
10 STRUCTURE AND FUNCTION…532
PARTS RELATED TO ENGINE…533
RADIATOR, OIL COOLER…536
POWER TRAIN…539
FINAL DRIVE…540
SWING CIRCLE…545
SWING MACHINERY…546
TRACK FRAME, RECOIL SPRING…549
TRACK SHOE…552
HYDRAULIC PIPING DRAWING…553
HYDRAULIC CIRCUIT DIAGRAM…555
HYDRAULIC TANK AND FILTER…556
HYDRAULIC PUMP…557
CONTROL VALVE…577
SELF REDUCING PRESURE VALVE…585
SUCTION SAFETY VALVE…590
CLSS…592
SWING MOTOR…635
CENTER SWIVEL JOINT…639
TRAVEL MOTOR…640
VALVE CONTROL…658
WORK EQUIPMENT PPC VALVE…659
TRAVEL PPC VALVE…663
PPC SAFETY LOCK VALVE…669
PPC ACCUMULATOR…670
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE…671
LS-EPC VALVE…678
SOLENOID VALVE…681
BOOM HOLDING VALVE…683
WORK EQUIPMENT…686
AIR CONDITIONER…687
ELECTRICAL WIRING SCHEMATIC…688
ELECTRICAL WIRING DIAGRAM…689
ENGINE CONTROL…692
ELECTRONIC CONTROL SYSTEM…699
MACHINE MONITOR CONTROL…722
20 TESTING AND ADJUSTING…732
TESTING AND ADJUSTING…732
STANDARD VALUE TABLE FOR ENGINE…733
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…734
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…739
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…745
MEASURING ENGINE SPEED…746
INTAKE MAIFOLD PRESSURE…747
INTAKE AIR RESTRICTION…747
LUBRICATING OIL PRESSURE…747
FUEL [FILTER] INLET RESTRICTION…747
BLOW BY PRESSURE…748
ENGINE BACK PRESSURE…748
COOLANT TEMPERATURE…748
VALVE CLEARANCE…748
MEASURING EXHAUST COLOR…749
GOVERNOR MOTOR LEVER STROKE…750
WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…751
TVC VALVE OUTPUT PRESSURE…754
LS VALVE OUTPUT PRESSURE…756
LS DIFFERENTIAL PRESURE…756
CONTROL CIRCUIT OIL PRESSURE…759
SOLENOID VALVE OUTPUT PRESSURE…760
PPC VALVE OUTPUT PRESSURE AND PPC SHUTTLE VALVE…763
WORK EQUIPMENT, SWING PPC VALVE…765
TRAVEL DEVIATION…766
HYDRAULIC DRIFT OF WORK EQUIPMENT…767
MEASURING OIL LEAKAGE…769
RELEASING REMAINING PRESSURE…772
SWING CIRCLE BEARING…773
WEAR OF SPROCKET…774
TRACK SHOE TENSION…775
BLEEDING AIR…776
TROUBLESHOOTING…779
TESTING AND ADJUSTMENT…744
TOOLS FOR TESTIN, ADJUSTING AND TROUBLESHOOTING…745
MEASURING ENGINE SPEED…746
INTAKE MANIFOLD PRESSURE…747
INTAKE AIR RESTRICTION…747
LUBRICATING OIL PRESSURE…747
FUEL [FILTER] INLET RESTRICTION…747
BLOW BY PRESSURE…748
ENGINE BACK PRESSURE…748
COOLANT TEMPERATURE…748
VALVE CLEARANCE…748
MEASURING EXHAUST COLOR…749
GOVERNOR MOTOR LEVER STROKE…750
WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…751
TVC VALVE OUTPUT PRESSURE…754
LS VALVE OUTPUT PRESSURE AN DLS DIFFERENTIAL PRESSURE…756
CONTROL CIRCUIT OIL PRESSURE…759
SOLENOID VALVE OUPUT PRESSURE…760
PPC VALVE OUTPUT PRESSURE AND PPC SHUTTLE VALVE…763
WORK EQUIPMENT, SWING PPC VALVE…765
TRAVEL DEVIATION…766
LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…767
MEASURING OIL LEAKAGE…769
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…772
TESTING CLEARANCE OF SWING CIRCLE BEARING…773
WEAR OF SPROCKET…774
TRACK SHOE TENSION…775
BLEEDING AIR…776
TROUBLESHOOTING…779
POINTS TO REMEMBER WHEN TROUBLESHOOTING…780
SEQUENCE OF EVENTS IN TROUBLESHOOTING…781
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…782
CHECKS BEFORE TROUBLSHOOTING…791
CONNECTOR TYPES AND MOUNTING LOCATIONS…792
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…795
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM…805
DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL…806
METHOD OF USING JUDGEMENT TABLE…814
METHOD OF USING TROUBLSHOOTING CHARTS…816
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE…819
SERVICE CODE TABLE…823
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM N MODE…824
N-1 [E218] COMMUNICATION ABNORMALITY…825
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER GOVEROR CONTROL SYSTEM E MODE…827
POINTS TO REMEMBER…828
ACTIONS TAKEN…829
JUDGEMENT TABLE…831
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM…832
E-1 ABNORMAILITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE, CONTROLLER LED IS OFF…833
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED…834
E-3 [E317] ABNORMALITY, DISCONNECTION IN MOTOR DRIVE SYSTEM IS DISPLAYED…835
E-4 [E318] ABNORMALITY, SHORT CIRCUIT IN MOTOR DRIVE SYSTEM IS DISPLAYED…836
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED…837
E-6 [E315] ABNORMALITY, SHORT CIRCUIT IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED…838
E-7 [E316] ABNORMALITY, STEP OUT IN MOTOR DISPLAYED…839
E-8 ENGINE DOES NOT START…840
E-9 ENGINE SPEED IS IRREGULAR…842
E-10 LACK OF OUTPUT, ENGINE HIGH IDLE SPEED IS TO LOW…844
E-11 ENGINE DOES NOT STOP…845
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM, ENGINE DOES NOT STOP…846
TROUBLESHOOTING OF ENGINE SYSTEM S MODE…848
METHOD OF USING CHARTS…849
S-1 STARTING PERFORMANCE IS POOR, STARTING ALWAYS TAKES TIME…853
S-2 ENGINE DOES NOT START…854
S-3 ENGINE DOES NOT PICK UP SMOOTHLY, FOLLOW UP IS POOR…857
S-4 ENGINE STOPS DURING OPERATION…858
S-5 ENGINE DOES NOT ROTATE SMOOTHLY, HUNTING…859
S-6 ENGINE LACKS OUTPUT, NO POWER…860
S-7 ENGINE SMOKE IS BLACK, INCOPLETE COMBUSTION…861
S-8 OIL CONSUMPTIONIS EXCESSIVE, OR EXHAUST SMOKE IS BLUE…862
S-9 OIL BECOMES CONTAMINATED QUICKLY…862
S-1O FUEL CONSUMPTION IS EXCESSIVE…862
S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN…862
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP, DROP IN OIL PRESSURE…862
S-13 OIL LEVEL RISES; COOLANT, FUEL IN OIL…863
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH; OVERHEATING…864
S-15 ABNORMAL NOISE IS MADE…865
S-16 VIBRATION IS EXCESSIVE…866
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER, PUMP CONTROL SYSTEM C MODE…867
POINTS TO REMEMBER…868
ACTIONS TAKEN BY CONTROLLER…869
JUDGEMENT TABLE…873
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE…874
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM, CONTROLLER LED IS OFF…876
C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED…877
C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID IS DISPLAYED…878
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED…879
C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED…880
C-6 [E207] SHORT CIRCUIT IN LS SELECT SOLENOID SYSTEM IS DISPLAYED…881
C-7 [E208] DISCONNECTION IN ACTIVE MODE, BOOM, SOLENOID SYSTEM IS DISPLAYED…883
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…884
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…885
C-10 [E204] SHORT CIRCUIT IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED…886
C-11 [E214] DISCONNECTION IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED…887
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPED SOLENOIDSYSTEM IS DISPLAYED…888
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED…889
C-14 [E217] SHORT CIRCUIT IN ACTIVE MODE, SWING, SOLENOID SYSTEM IS DISPLAED…890
C-15 [E235] DISCONNECTION IN ACTIVE MODE, SWING, SOLENOID SYSTEM IS DISPLAYED…891
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED…892
C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYTEM IS DISPLAYED…894
C-18 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…895
C-19 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…896
C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…897
C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED…898
C-22 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED…899
C-23 ABNORMALITY IN MACHINE PUSH UP SOLENOID SYSTEM , NO SERVICE CODE DISPLAYED…900
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER, INPUT SIGNAL SYSTEM F MODE…902
ELECTRIC CIRCUIT DIAGRAM FOR F MODE…904
F-1 BIT PATTERN 20-[1] SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP…905
F-2 BIT PATTERN 20-[2] TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP…906
F-3 BIT PATTERN 20-[3] BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP…907
F-4 BIT PATTERN 20-[4] BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP…908
F-5 BIT PATTERN 20-[5] ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP…909
F-6 BIT PATTERN 20-[6] ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP…910
F-7 BIT PATTERN 21-[1] BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP…911
F-8 BIT PATTERN 21-[2] BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP…912
F-9 BIT PATTERN 21-[3] SWING LOCK SWITCH DOES NOT LIGHT UP…913
F-10 BIT PATTERN 22-[5] MODE CONNECTION DOES NOT LIGHT UP…914
F-11 BIT PATTERN 22-[6] LEFT KNOB SWITCH DOES NOT LIGHT UP…915
TROUBLESHOOTING OF MACHINE MECHANICAL SYSTEM H MODE…916
PUMP MERGE DIVIDER LOGIC…917
SOLENOID ACTUATION TABLE…917
TABLE OF FAILURE MODES AND CAUSES…918
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…920
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…921
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVEMENT…921
H-4 ABNORMAL NOISE GENERATED AROUND PUMP…922
H-5 AUTO DECELERATION DOES NOT WORK, WHEN PPC SHUTTLE VALVE IS CAUSE…922
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…922
H-7 BOOM IS SLOW OR LACKS POWER…923
H-8 ARM IS SLOW OR LACKS POWER…924
H-9 BUCKET IS SLOW OR LACKS POWER…925
H-10 WORK EQUIPMENT; BOOM, ARM, BUCKET, DOES NOT MOVE, BUT TRAVEL AND SWING ARE NORMAL…926
H-11 EXCESSIVE HYDRAULIC DRIFT, BOOM, ARM, BUCKET…926
H-12 EXCESSIVE TIME LAG, ENGINE AT LOW IDLING…927
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED…927
H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEE…928
H-15 MALFUNCTION OF MACHINE PUSH UP FUNCTION…928
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…928
H-17 IN SWING PLUS BOOM RAISE, BOOM RAISE IS SLOW…929
H-18 IN SWING PLUS ARM, ARM IS SLOW…929
H-19 IN SWING PLUS TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY…929
H-20 TRAVEL DEVIATION…930
H-21 TRAVEL SPEED IS LOW…932
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER…933
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED…934
H-24 TRAVEL DOES NOT MOVE, ONE SIDE ONLY…934
H-25 DOES NOT SWING…935
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW…936
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING…937
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING, ONE DIRECTION ONLY…938
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…938
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING…939
H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED…939
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM M MODE…940
ACTIONS TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…940
ELECTRIC CIRCUIT DIAGRAM FOR M MODE…943
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED…944
[E101] ERROR IN CLOCK DATA IS DISPLAYED…944
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR 24V WIRING HARNESS CONTACKT WITH BUZZERNESS IS DISPLAYED…945
M3 [E104] AIR CLEANER RESTRICTION DETECTED IS DISPLAYED…946
M4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED…946
M5 [E108] ENGINE COOLANT TEMPERATURE 1O5 DEGREES CELS DETECTED IS DISPLAYEDIUS…946
M-6 WHEN START SWITCH IS TURNED ON, NO LAMPS ON MONITOR PANEL LIGHT UP FOR THREE SECONDS…947
M-7 WHEN START SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY ILLUMINATED AND DO NOT GO OUT…949
M-8 WHEN START SWITCH IS TURNED ON, ITEMS ILLUMINATED ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE…949
M-9 WHEN START SWITCH IS TURNED ON, ENGINE STOPPED, BASIC CHECK ITEMS FLASH…950
M-10 PREHEATING IS NOT USED, BUT MONITOR PANEL LIGHTS UP…953
M-11 WHEN START SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH…954
M-12 WHEN START SWITCH IS TURNED ON, ENG. SPEED, CAUTION ITEMS, EMERGENCY ITEMS FLASH. BATTERY ENG. OIL PRESSURE LAMPS DO NOT …956
M-13 WHEN START SWITCH IS TURNED ON AND ENG. IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH, WHEN THERE IS NO ABNORMALTY IN E…958
M-14 WHEN START SWITCH IS TURNED ON, ENG. STOPPED, BUZZER DOES NOT SOUND FOR ONE SECOND, CAUTION ITEMS FLASH BUT DO NOT SOUND…961
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR PANEL BUT BUZZER SOUNDS…962
M-16 NIGHT LIGHT ON MONITOR PANEL DOES NOT LIGHT UP, LIQUID CRYSTAL DISPLAY IS NORMAL…963
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE…964
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY, NO GUAGE LAMPS LIGH UP DURING OPERATION…965
M-19 FUEL LEVEL GUAGE ALWAYS DISPLAYS FULL…966
M-20 FUEL LEVEL GUAGE DOES NOT GIVE DISPLAY…967
M-21 SWING LOCK SWITCH IS TURNED ON, BUT MONITOR PANEL DOES NOT LIGHT …968
M-22 SWING PROLIX SWITCH IS TURNED ON, BUT MONITOR PANEL DOES NOT FLASH…969
M-23 SERVICE METER DOES NOT ADVANCE WHIL ENGINE IS RUNNING…970
M-24 WHEN START SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED…970
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM…971
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM…972
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM…973
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM…974
M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM…975
M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED [INCLUDE E112, E113]…976
M-31 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED [INCLUDEE114]…980
30 DISASSEMBLY AND ASSEMBLY…982
METHOD OF USING MANUAL…983
PRECAUTIONS…985
SPECIAL TOOL LIST…988
SKETCHES OF SPECIAL TOOLS…995
ENGINE COMPONENTS…1003
GOVERNOR MOTOR…1006
OIL COOLER…1007
RADIATOR, OIL COOLER…1008
ENGINE, MAIN PUMP…1010
DAMPER…1014
FUEL TANK…1015
CENTER SWIVEL JOINT…1016
FINAL DRIVE – PC300LC-6…1018
FINAL DRIVE – PC300HD-6…1029
TRAVEL MOTOR – PC300LC-6…1040
TRAVEL MOTOR – PC300HD-6…1053
SPROCKET…1066
SWING MOTOR…1067
SWING MACHINERY…1077
REVOLVING FRAME…1086
SWING CIRCLE…1088
IDLER AND RECOIL SPRING- PC300LC-6…1089
IDLER AND RECOIL SPRING – PC300HD-6…1090
IDLER – PC300LC-6…1091
IDLER – PC300HD-6…1094
RECOIL SPRING…1098
TRACK ROLLER…1100
CARRIER ROLLER…1105
TRACK CHAIN…1110
HYDRAULIC TANK…1111
MAIN PUMP…1113
MAIN PUMP OIL SEAL…1140
CONTROL VALVE…1141
PUMP MERGE DIVIDER VALVE…1155
PRESSURE COMPENSATION VALVE…1156
FRONT PUMP SERVO VALVE…1157
REAR PUMP SERVO VALVE…1158
LS-EPC SOLENOID VALVE…1159
SOLENOID VALVE…1160
WORK EQUIPMENT PPC VALVE…1161
TRAVEL PPC VALVE…1163
PPC SHUTTLE VALVE…1165
BOOM LOCK VALVE…1168
BOOM CYLINDER…1170
ARM CYLINDER…1172
BUCKET CYLINDER…1173
HYDRAULIC CYLINDER…1175
WORK EQUIPMENT…1185
BUCKET…1187
ARM…1189
BUCKET AND ARM…1191
BOOM…1193
OPERATORS CAB…1195
COUNTERWEIGHT…1197
COMPRESSOR…1198
CONDENSER…1199
RECEIVER TANK…1200
AIR CONDITIONER UNIT…1201
GOVERNOR, PUMP CONTROLLER…1203
MONITOR PANEL…1204
CONTROL STAND CASE…1205
40 MAINTENANCE STANDARD…1207
ENGINE MOUNT…1208
SWING MACHINERY…1212
SWING CIRCLE…1214
FINAL DRIVE – PC300LC-6…1216
FINAL DRIVE – PC300HC-6…1218
TRACK FRAME AND RECOIL SPRING…1220
IDLER – PC300LC-6…1222
IDLER – PC300HD-6…1224
CARRIER ROLLER…1226
TRACK ROLLER – PC300LC-6…1228
TRACK ROLLER – PC300HD-6…1229
TRACK SHOE…1230
HYDRAULIC PUMP…1235
CONTROL VALVE…1236
SELF REDUCING PRESSURE VALVE…1243
SUCTION SAFETY VALVE…1244
SWING MOTOR…1245
TRAVEL MOTOR – PC300LC-6…1246
TRAVEL MOTOR – PC300HD-6…1247
WORK EQUIPMENT – SWING PPC VALVE…1248
TRAVEL PPC VALVE…1249
SERVICE PPC VALVE…1250
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE…1251
LS-EPC VALVE…1252
SOLENOID VALVE…1253
CENTER SWIVEL JOINT…1254
BOOM HOLDING VALVE…1255
HYDRAULIC CYLINDER…1256
WORK EQUIPMENT…1258
DIMENSIONS OF WORK EQUIPMENT…1260
90 OTHER…1264
FOLDOUT 1 HYDRAULIC SCHEMATIC…1264
FOLDOUT 2 ELECTRICAL WIRING SCHEMATIC (2/3)…1268
FOLDOUT 3 ELECTRICAL WIRING SHCEMATIC (3/3)…1272
CEBM009500 – Logging Excavator PC300LL-6 avance Shop Manual…1275
COVER…1275
CONTENTS…1276
FOREWORD…1279
SAFETY…1279
SAFETY NOTICE…1279
IMPORTANT SAFETY NOTICE…1279
GENERAL PRECAUTIONS…1279
PREPARATIONS FOR WORK…1279
PRECAUTIONS DURING WORK…1279
GENERAL…1281
HOW TO READ THE SHOP MANUAL…1282
VOLUMES…1282
DISTRIBUTION AND UPDATING…1282
FILING METHOD…1282
REVISED EDITION MARK…1282
REVISIONS…1282
SYMBOLS…1282
HOISTING INSTRUCTIONS…1283
HOISTING…1283
WIRE ROPES…1283
COATING MATERIALS…1284
STANDARD TIGHTENING TORQUE…1286
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS…1286
TIGHTENING TORQUE OF HOSE NUTS…1287
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…1287
TIGHTENING TORQUE FOR FLARED NUTS…1287
ALTERNATIVE FASTENERS…1288
BOLT IDENTIFICATION CHART…1288
GRADE 5 AND 8 NON PHOSPHATE COATED HARDWARE…1289
GRADE 8 PHOSPHATE COATED HARDWARE…1290
STANDARD METRIC FASTENERS…1290
HYDRAULIC TUBES AND FITTINGS…1291
HOSE CLAMPS…1291
SPLIT FLANGE CONNECTIONS…1291
ELECTRIC WIRE CODE…1292
CLASSIFICATION BY THICKNESS…1292
CLASSIFICATION BY COLOR AND CODE…1292
CONVERSION TABLES…1293
METHOD OF USING THE CONVERSION TABLE…1293
01 GENERAL…1276
GENERAL ASSEMBLY DRAWING…1300
PC300LL-6…1300
SPECIFICATIONS…1302
PC300LL-6…1302
WEIGHT TABLE…1303
10 STRUCTURE AND FUNCTION…1305
SWING CIRCLE…1306
SWING MACHINERY…1307
TRACK FRAME • RECOIL SPRING…1308
SWING MOTOR…1309
KMF160ABE-3…1309
SUCTION-SAFETY VALVE…1311
SWING BRAKE…1312
CAB RISER AND RELATED PARTS…1313
30 DISASSEMBLY AND ASSEMBLY…1317
SWING MOTOR…1318
REMOVAL…1318
INSTALLATION…1318
DISASSEMBLY…1319
ASSEMBLY…1321
SWING MACHINERY…1328
REMOVAL…1328
INSTALLATION…1328
DISASSEMBLY…1329
ASSEMBLY…1332
REVOLVING FRAME…1337
REMOVAL…1337
INSTALLATION…1338
SWING CIRCLE…1339
REMOVAL…1339
INSTALLATION…1339
IDLER AND RECOIL SPRING…1340
REMOVAL…1340
INSTALLATION…1340
RECOIL SPRING…1341
DISASSEMBLY…1341
ASSEMBLY…1342
COUNTERWEIGHT…1343
REMOVAL…1343
INSTALLATION…1343
40 MAINTENANACE STANDARD…1345
SWING MACHINERY…1346
SWING CIRCLE…1347
SWING MOTOR…1348
KMF160ABE 3…1348
CEBM018703 – Hydraulic Excavator PC300LC-8, PC300HD-8 Shop Manual…1351
CEBM018703 – PC300LC/HD-8…1351
CONTENTS…1352
REVISED PAGES…1353
SAFETY…1363
Safety Notice…1363
IMPORTANT SAFETY NOTICE…1363
General Precautions…1363
Preparations For Work…1363
Precautions During Work…1363
GENERAL…1365
HOW TO READ THE SHOP MANUAL…1366
Volumes…1366
Distribution and Updating…1366
Filing Method…1366
Revised Edition Mark…1366
Revisions…1366
Symbols…1366
HOISTING INSTRUCTIONS…1367
Hoisting…1367
Wire Ropes…1367
PUSH PULL COUPLER…1368
Type 1…1368
Disconnection…1368
Connection…1368
Type 2…1369
Disconnection…1369
Connection…1369
Type 3…1370
Disconnection…1370
Connection…1370
COATING MATERIALS…1371
STANDARD TIGHTENING TORQUE…1373
Standard Tightening Torque of Bolts And Nuts…1373
Tightening Torque of Hose Nuts…1374
Tightening Torque of Split Flange Bolts…1374
Tightening Torque for Flared Nuts…1374
Table of Tightening Torques for O-ring Boss Piping Joints…1375
Table of Tightening Torques for O-ring Boss Plugs…1375
Tightening Torque Table for Hoses (Taper Seal Type and Face Seal Type)…1375
ELECTRIC WIRE CODE…1376
Classification by Thickness…1376
Classification by Color and Code…1376
CONVERSION TABLES…1377
Method of Using the Conversion Table…1377
01 GENERAL…1383
SPECIFICATION DIMENSION DRAWINGS…1384
Dimensions…1384
Working Ranges…1385
SPECIFICATIONS…1386
WEIGHT TABLE…1389
FUEL, COOLANT, AND LUBRICANTS…1391
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD…1393
ENGINE AND COOLING SYSTEM…1396
Engine Related Parts…1396
Radiator, Oil Cooler and Aftercooler…1397
POWER TRAIN…1398
Power Train…1398
Final Drive…1400
PC300LC-8…1400
PC300HD-8…1402
Sprocket…1404
PC300LC-8…1404
PC300HD-8…1406
Swing Machinery…1408
Swing Circle…1410
UNDERCARRIAGE AND FRAME…1412
Track Frame and Recoil Spring…1412
PC300LC-8…1412
PC300HD-8…1414
Idler…1416
PC300LC-8…1416
PC300HD-8…1418
Carrier Roller…1420
PC300LC-8…1420
PC300HD-8…1421
Track Roller…1422
PC300LC-8…1422
PC300HD-8…1424
Track Shoe…1426
PC300LC-8…1426
PC300HD-8…1428
Triple Grouser Shoe…1430
PC300LC-8…1430
PC300HD-8…1431
HYDRAULIC SYSTEM…1432
Hydraulic Equipment Layout Drawing…1432
Hydraulic Tank and Filter…1434
Hydraulic Pump…1436
Type: HPV125+125…1436
LS Valve…1442
PC Valve…1447
LS(PC)-EPC Valve…1454
Variable Volume Valve…1457
Control Valve…1458
CLSS (Closed Center Load Sensing System)…1470
Valve Functions and Operation…1474
Hydraulic Circuit Diagram and the Name of Valves…1474
Unloader Valve…1476
LS Pressure…1478
Pressure Compensation Valve…1480
Pressure Compensation Valve Inner Shuttle…1483
Boom Regeneration Circuit…1485
Arm Regeneration Circuit…1487
Merge-divider Valve…1489
LS Select Valve…1491
Self Pressure Reducing Valve…1492
Travel Junction Valve…1495
Travel PPC Shuttle Valve…1497
Boom Drift Prevention Valve…1499
Arm Drift Prevention Valve…1502
Quick Return Valve…1506
Lift Check Valve…1508
Main Relief Valve…1509
2-Stage Safety-suction Valve…1510
Variable Pressure Compensation Valve…1512
Attachment Circuit Selector Valve…1514
Drift Prevention Valve…1516
Valve Control…1521
PPC Valve…1522
Travel PPC Valve…1527
Pressure Reducing Valve…1530
Service PPC Valve (with EPC Valve)…1536
Service PPC Valve…1542
Solenoid Valve…1544
PPC Accumulator…1546
Return Oil Filter…1547
Center Swivel Joint…1548
Travel Motor – Type: HMV160ADT-2 – PC300LC-8…1550
Parking Brake – PC300LC-8…1556
Travel Motor – Type: KMV200ADT-2 – PC300HD-8…1564
Parking Brake – PC300HD-8…1570
Safety Valve…1574
Swing Motor…1578
Reverse Prevention Valve…1584
Hydraulic Cylinder…1588
Boom Cylinder…1588
Arm Cylinder…1588
Bucket Cylinder…1588
WORK EQUIPMENT…1590
Work Equipment…1590
Dimension Of Arm…1592
Dimension Of Bucket…1594
AIR CONDITIONER PIPING…1596
ELECTRICAL SYSTEM…1597
Engine Control…1597
Fuel Control Dial…1599
Engine Controller…1600
Sensors…1604
Coolant Temperature Sensor…1604
Oil Pressure Switch…1604
Engine Speed Sensor…1605
Boost Pressure And Temperature Sensor…1605
WIF (Water-in-fuel Detection) Sensor…1606
Engine Oil Level Sensor…1606
ELECTRONIC CONTROL SYSTEM…1607
Control Function…1607
System Diagram…1608
Engine and Pump Control…1610
Pump and Valve Control…1616
LS Control Function…1617
Cut-off Function…1617
2-Stage Relief Function…1617
Power Maximizing and Machine Push-up…1618
Auto-deceleration…1620
Auto-warm-up and Overheat Prevention…1622
Swing Control…1624
Travel Control…1626
Attachment Flow Control and Circuit Selector…1628
System Component Parts…1629
PPC Oil Pressure Switch…1629
Oil Pressure Sensor…1630
Pump Pressure Sensor (High Pressure)…1631
Pump Controller…1632
MONITOR SYSTEM…1635
Machine Monitor…1636
Monitor Control, Display Portion…1640
Monitor Items And Display…1642
Switches…1646
Sensors…1663
KOMTRAX Terminal System…1665
KOMTRAX Communication Modem – TH300…1666
20 STANDARD VALUE TABLES…1667
STANDARD VALUE TABLES…1668
Engine Related…1668
Chassis Related…1669
30 TESTING AND ADJUSTING…1677
CHASSIS SERVICE TOOLS…1679
Sketches of special tools…1683
ENGINE…1684
Engine Speed…1684
Air Boost Pressure…1685
Exhaust Gas Color…1686
Valve Clearance…1688
Compression Pressure…1690
Blow-by Pressure…1695
Engine Oil Pressure…1696
Fuel Pressure…1697
Handling During Cylinder Cut-out Operation…1702
Handling During No Injection Cranking Operation…1702
Fuel Return Rate And Leakage…1703
Bleeding Air From Fuel Circuit…1706
Fuel Circuit For Leakage…1707
AIR COMPRESSOR BELT TENSION…1708
FAN BELT…1709
ALTERNATOR BELT…1710
SWING CIRCLE BEARINGS…1711
TRACK SHOE TENSION…1712
OIL PRESSURE IN WORK EQUIPMENT…1713
OIL PRESSURE IN SWING…1713
OIL PRESSURE IN TRAVEL CIRCUIT…1713
CONTROL CIRCUIT OIL PRESSURE…1718
PUMP PC OIL PRESSURE…1719
PUMP LS OIL PRESSURE…1722
SOLENOID VALVE OUTPUT PRESSURE…1727
PPC VALVE OUTPUT PRESSURE…1730
WORK EQUIPMENT VALVE ADJUSTMENT…1731
SWING PPC VALVE ADJUSTMENT…1731
HYDRAULIC DRIFT IN WORK EQUIPMENT…1732
Boom and Bucket Cylinders…1732
Arm Cylinder…1732
Boom Lock Valve…1733
PPC Valve…1733
RELEASING HYDRAULIC PRESSURE…1734
Oil Leakage Amount…1734
BLEEDING AIR FROM VARIOUS SYSTEMS…1737
DIODE INSPECTION PROCEDURES…1740
MACHINE MONITOR – SPECIAL FUNCTIONS…1742
Ordinary Functions and Special Functions of Machine Monitor…1744
Operator Mode (Outline)…1746
Display of Komatsu Logo…1747
Display of Inputting Password…1747
Display of Check of Breaker Mode…1748
Display of Check Before Starting…1748
Display of Warning After Check Before Starting…1748
Display of Ending of Maintenance Interval…1749
Display of Check of Working Mode and Travel Speed…1749
Display of Ordinary Screen…1749
Display of End Screen…1750
Selection of Auto-deceleration…1750
Selection of Working Mode…1750
Selection of Travel Speed…1751
Operation to Stop Alarm Buzzer…1751
Operation of Windshield Wiper…1752
Operation of Window Washer…1752
Operation of Air Conditioner/heater…1752
Operation to Display Camera Mode (if CameraiIs Installed)…1753
Operation to Display Clock and Service Meter…1753
Check of Maintenance Information…1754
Setting and Display of User Mode…1754
KOMTRAX Message…1755
Display of Energy-saving Guidance…1755
Display of Caution Monitor…1755
Display of Automatic Judgment of Breaker…1756
Display of User Code and Failure Code…1756
Function of Checking Display of LCD (Liquid Crystal Display)…1758
Function of Checking Service Meter…1758
Function of Changing Attachment/Maintenance Password…1759
Service Mode…1761
Monitoring…1763
Abnormality Record (Mechanical Systems)…1768
Abnormality Record (Electrical Systems)…1769
Abnormality Record (Air-conditioning System/Heater System)…1777
Maintenance Record…1778
Maintenance Mode Change…1779
Phone Number Entry…1782
Default (Key-ON Mode)…1783
Default (Unit)…1784
Default (With/Without Attachment)…1785
Default (Attachment/Maintenance Password)…1786
Default (Camera)…1787
Default (ECO Display)…1788
Default (Breaker Detect)…1790
Adjustment (Pump Absorption Torque)…1791
Adjustment (Low Speed)…1792
Adjustment (Attachment Flow Adjustment)…1793
Cylinder Cut-Out…1794
No Injection…1795
Fuel Consumption…1797
KOMTRAX Settings (Terminal Status)…1798
KOMTRAX Settings (GPS & Communication Status)…1799
KOMTRAX Setting (Modem S/N: TH300)…1800
Display of KOMTRAX Service Message…1801
Long Distance Transport Mode…1802
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…1804
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…1805
PROCEDURE FOR TESTING DIODES…1810
PM CLINIC SERVICE…1811
40 TROUBLESHOOTING…1817
FAILURE CODES TABLE…1821
FUSE LOCATIONS…1824
Connection Table of Fuse Box…1824
Locations of Fusible Links…1825
Location of Fuse Box and Fuse Numbers…1825
GENERAL INFORMATION…1828
Points to Remember when Troubleshooting…1828
Sequence of Events in Troubleshooting…1830
Handling Electric Equipment and Hydraulic Components…1831
Connectors for Tier 3 Engines…1839
Checks Before Troubleshooting…1843
Classification and Troubleshooting Steps…1844
Classification of Troubleshooting…1844
Information in Troubleshooting Table…1846
Possible Problems and Troubleshooting No…1848
Connection Table for Connector Pin Numbers…1851
T-adapter Box and T-adapter Table…1886
FAILURE CODE (DISPLAY OF CODE)…1889
989L00 – Engine Controller Lock Caution 1…1889
989L00 – Engine Controller Lock Caution 2…1889
989L00 – Engine Controller Lock Caution 3…1890
AA10NX – Air Cleaner Clogging…1892
AB00KE – Charge Voltage Low…1894
B@BAZG – Engine Oil Pressure Low…1896
B@BAZK – Engine Oil Level Low…1898
B@BCNS – Engine Coolant Overheat…1900
B@BCZK – Engine Coolant Level Low…1902
B@HANS – Hydraulic Oil Overheat…1904
CA111 – EMC Critical Internal Failure…1906
CA115 – Engine NE and BKUP Speed Sensor Error…1907
CA122 – Charge Air Pressure Sensor High Error…1908
CA123 – Charge Air Pressure Sensor Low Error…1910
CA131 – Throttle Sensor High Error…1912
CA132 – Throttle Sensor Low Error…1914
CA144 – Coolant Temperature Sensor High Error…1916
CA145 – Coolant Temperature Sensor Low Error…1918
CA153 – Charge Air Temperature Sensor High Error…1920
CA154 – Charge Air Temperature Sensor Low Error…1922
CA155 – Chg Air Temp High Speed Derate…1924
CA187 – Sensor Power Supply Two Volt Low Error…1926
CA221 – Ambient Pressure Sensor High Error…1928
CA222 – Ambient Pressure Sensor Low Error…1930
CA227 – Sensor Supply Two Volt High Error…1932
CA234 – Engine Overspeed…1934
CA238 – NE Speed Sensor Supply Voltage Error…1935
CA271 – IMV/PCV1 Short Error…1936
CA272 – IMV/PCV1 Open Error…1938
CA281 – Pump Press Balance Error…1940
CA322 – Injector #1 Open/short Error…1942
CA323 – Injector #5 Open/short Error…1944
CA324 – Injector #3 Open/short Error…1946
CA325 – Injector #6 Open/short Error…1948
CA331 – Injector #2 Open/short Error…1950
CA332 – Injector #4 Open/short Error…1952
CA342 – Calibration Code Incompatibility…1954
CA351 – Injectors Drive Circuit Error…1956
CA352 – Sensor Supply One Volt Low Error…1958
CA386 – Sensor Supply One Volt High Error…1960
CA428 – Water in Fuel Sensor High Error…1962
CA429 – Water in Fuel Sensor Low Error…1964
CA435 – Eng Oil Press Sw Error…1966
CA441 – Battery Voltage Low Error…1968
CA442 – Battery Voltage High Error…1970
CA449 – Rail Pressure Very High Error…1972
CA451 – Rail Pressure Sensor High Error…1976
CA452 – Rail Pressure Sensor Low Error…1978
CA488 – Chg Air Temp High Torque Derate…1980
CA553 – Rail Pressure High Error…1981
CA559 – Rail Pressure Low Error…1982
CA689 – Engine NE Speed Sensor Error…1984
CA731 – Engine BKUP Speed Sensor Phase Error…1986
CA757 – All Persistent Data Lost Error…1988
CA778 – Engine BKUP Speed Sensor Error…1990
CA1633 – KOMNET Datalink Timeout Error…1992
CA2185 – Throttle Sensor Supply Volt High Error…1994
CA2186 – Throttle Sensor Supply Volt Low Error…1996
CA2249 – Rail Pressure Very Low Error…1997
CA2265 – Electric Lift Pump High Error…1998
CA2266 – Electric Lift Pump Low Error…2000
CA2311 – IMV Solenoid Error…2002
CA2555 – Grid Htr Relay Volt High Error…2004
CA2556 – Grid Htr Relay Volt Low Error…2006
D110KB – Battery Relay Drive S/C…2008
D19JKZ – Personal Code Relay Abnormality…2010
D862KA – GPS Antenna Discon…2012
DA22KK – Pump Solenoid Power Low Error…2014
DA25KP – 5 V Sensor 1 Power Abnormality…2016
DA29KQ – Model Selection Abnormality…2020
DA2RMC – Pump Communication Abnormality…2022
DAF8KB – Short Circuit in Camera Power Supply…2024
DAFGMC – GPS Module Error…2026
DAFRMC – CAN Discon (Monitor Detected)…2028
DGH2KB – Hyd Oil Sensor Short…2030
DHPAMA – F Pump Pressure Sensor Abnormality…2032
DHPBMA – R Pump Pressure Sensor Abnormality…2034
DHS3MA – Arm Curl PPC Sensor Abnormality…2036
DHS4MA – Bucket Curl PPC Pressure Sensor Abnormality…2038
DHX1MA – Overload Sensor Abnormality (Analog)…2040
DW43KA – Travel Speed Solenoid Disconnection…2042
DW43KB – Travel Speed Solenoid S/C…2044
DW45KA – Swing Brake Solenoid Disconnection…2046
DW45KB – Swing Brake Solenoid S/C…2050
DW91KA – Travel Junction Solenoid Disconnection…2052
DW91KB – Travel Junction Solenoid S/C…2054
DWA2KA – Attachment Sol Open Circuit…2056
DWA2KB – Attachment Sol Short Circuit…2057
DWJ0KA – Merge-Divider Solenoid Disconnection…2058
DWJ0KB – Merge-Divider Solenoid S/C…2060
DWK0KA – 2-Stage Relief Sol. Open Circuit…2062
DWK0KB – 2-Stage Relief Solenoid Short Circuit…2064
DXA0KA – PC-EPC Solenoid Open Circuit…2066
DXA0KB – PC-EPC Solenoid Short Circuit…2068
DXE0KA – LS-EPC Solenoid Disconnection…2070
DXE0KB – LS-EPC Solenoid Short Circuit…2072
DXE4KA – Service Current EPC Disconnection…2074
DXE4KB – Service Current EPC Short Circuit…2075
DY20KA – Wiper Working Abnormality…2076
DY20MA – Wiper Parking Abnormality…2078
DY2CKA – Washer Drive Open Circuit…2080
DY2CKB – Washer Drive Short Circuit…2082
DY2DKB – Wiper Motor Drive Forward System Short…2084
DY2EKB – Wiper Drive Reverse Short Circuit…2086
E-MODE (ELECTRICAL SYSTEM)…2088
Information Contained in Troubleshooting Table…2088
E-1 Engine Does Not Start…2090
E-2 Auto-decelerator Does Not Operate…2093
E-3 Automatic Warming-up System Does Not Operate…2095
E-4 Preheater Does Not Operate…2096
E-5 All Work Equipment, Swing, and Travel Mechanism do not move…2098
E-6 Power Maximizing Function Does Not Operate…2100
E-7 Machine Monitor Does Not Display At All…2102
E-8 Machine Monitor Does Not Display Some Items…2104
E-9 Contents of Display by Machine Monitor are Different from Applicable Machine…2104
E-10 Fuel Level Monitor Was Lit in Red While Engine Running…2105
E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally…2106
E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally…2108
E-13 Fuel Level Gauge Does Not Indicate Normally…2109
E-14 Swing Lock Monitor Does Not Indicate Normally…2110
E-15 When Monitor Switch is Operated, Monitor Displays Nothing…2112
E-16 Windshield Wiper and Window Washer do not Operate…2114
E-17 Machine Push-up Function Does Not Operate Normally…2118
E-18 Monitoring Function Fails to Display “Boom Raise” Normally…2120
E-19 Monitoring Function Fails to Display “Boom Lower” Normally…2122
E-20 Monitoring Function Fails to Display “Arm In” Normally…2124
E-21 Monitoring Function Fails to Display “Arm Out” Normally…2126
E-22 Monitoring Function Fails to Display “Bucket Curl” Normally…2128
E-23 Monitoring Function Fails to Display “Bucket Dump” Normally…2130
E-24 Monitoring Function Fails to Display “Swing” Normally…2132
E-25 Monitoring Function Fails to Display “Travel” Normally…2134
E-26 Monitoring Function Fails to Display “Travel Differential Pressure” Normally…2136
E-27 Monitoring Function Fails to Display “Service” Normally…2138
E-28 KOMTRAX System Does Not Operate Normally…2140
E-29 Air Conditioner Does Not Operate…2142
E-30 Travel Alarm Does Not Sound or Does Not Stop Sounding…2144
E-31 Horn Does Not Sound…2146
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)…2148
System Chart for Hydraulic and Mechanical System…2148
Information Contained in Troubleshooting Table…2150
H-1 All Work Equipment Lack Power, or Travel and Swing Speeds are Slow…2152
H-2 Engine Speed Sharply Drops or Engine Stalls…2154
H-3 No Work Equipment, Swing or Travel Move…2155
H-4 Abnormal Noise is Heard from Around Hydraulic Pump…2155
H-5 Auto-decelerator Does Not Work…2156
H-6 Fine Control Mode Does Not Function or Responds Slow…2156
H-7 Boom Moves Slowly or Lacks Power…2157
H-8 Arm Moves Slowly or Lacks Power…2158
H-9 Bucket Moves Slowly or Lacks Power…2159
H-10 Work Equipment Does Not Move in its Single Operation…2159
H-11 Work Equipment has a bit too Fast Hydraulic Drift…2160
H-12 Work Equipment Has Big Time Lag…2162
H-13 Other Work Equipment Moves When Relieving Single Circuit…2162
H-14 Power Max. Switch Does Not Operate…2163
H-15 In Compound Operation, Work Equipment with Larger Load Moves Slowly…2163
H-16 In Swing + Boom Raise Operation, Boom Moves Slowly…2164
H-17 In Swing + Travel Operation, Travel Speed Drops Sharply…2164
H-18 Machine Swerves in Travel…2165
H-19 Machine Travels Slowly…2166
H-20 Machine Cannot Be Easily Steered or Lacks Power…2167
H-21 Travel Speed Does Not Shift, or it is too Slow or Fast…2168
H-22 Track Shoe Does Not Turn (On One Side Only)…2169
H-23 Machine Does Not Swing…2170
H-24 Swing Acceleration is Poor, or Swing Speed is Slow…2172
H-25 Excessive Overrun When Stopping Swing…2174
H-26 There is Big Shock when Stopping Swing…2175
H-27 Large Sound is made when Upper Structure Stops Swinging…2175
H-28 Swing Hydraulic Drift is too big…2176
50 DISASSEMBLY AND ASSEMBLY…2177
HOW TO READ THIS MANUAL…2180
SPECIAL TOOLS LIST…2183
SKETCHES OF SPECIAL TOOLS…2187
CONNECTOR REPAIR PROCEDURES…2190
Contact Terminal Removal (HD30 Type)…2190
Striping Insulation…2191
Crimping Contact Terminal (HD30 Type)…2192
Insertion Of Contact Terminal (HD30 Type)…2193
Contact Terminal Removal (DT Type)…2194
ENGINE COMPONENTS…2195
Fuel Supply Pump…2195
Removal…2195
Installation…2197
Engine Front Seal…2199
Removal…2199
Installation…2201
Engine Rear Seal…2203
Removal…2203
Installation…2205
Cylinder Head…2209
Removal…2209
Installation…2215
RADIATOR…2224
Removal…2224
Installation…2225
HYDRAULIC OIL COOLER…2226
Removal…2226
Installation…2227
AFTERCOOLER…2228
Removal…2228
Installation…2228
ENGINE AND HYDRAULIC PUMP…2229
Removal…2229
Installation…2234
FINAL DRIVE…2235
Removal…2235
Installation…2235
Disassembly…2236
Assembly…2241
SWING MOTOR AND SWING MACHINERY…2248
Removal…2248
Installation…2249
Disassembly…2250
Assembly…2254
SWING CIRCLE…2260
Removal…2260
Installation…2260
CARRIER ROLLER…2261
Disassembly…2261
Assembly…2261
TRACK ROLLER…2263
Disassembly…2263
Assembly…2263
IDLER…2265
Disassembly…2265
Assembly…2266
RECOIL SPRING…2269
Disassembly…2269
Assembly…2270
SPROCKET…2272
Removal…2272
Installation…2272
TRACK SHOE…2273
Expansion…2273
Installation…2274
REVOLVING FRAME…2275
Removal…2275
Installation…2277
COUNTERWEIGHT…2278
Removal…2278
Installation…2279
CENTER SWIVEL JOINT…2280
Removal…2280
Installation…2281
Disassembly…2282
Assembly…2283
HYDRAULIC TANK…2284
Removal…2284
Installation…2286
CONTROL VALVE…2287
Removal…2287
Installation…2290
Disassembly…2290
Assembly…2290
HYDRAULIC PUMP…2293
Removal…2293
Installation…2295
Oil Seal in Hydraulic Pump input Shaft…2296
Removal…2296
Installation…2296
WORK EQUIPMENT PPC VALVE…2297
Disassembly…2297
Assembly…2297
TRAVEL PPC VALVE…2300
Disassembly…2300
Assembly…2301
HYDRAULIC CYLINDER…2303
Disassembly…2303
Assembly…2306
WORK EQUIPMENT…2310
Removal…2310
Installation…2312
CAB…2313
Removal…2313
Installation…2316
Cab Glass (Stuck Glass)…2317
Removal…2318
Installation…2319
Front Window…2329
Removal…2329
Installation…2332
Floor Frame…2337
Removal…2337
Installation…2341
ELECTRICAL SYSTEM…2342
Air Conditioner Unit…2342
Removal…2342
Installation…2345
KOMTRAX Communication Modem…2346
Removal…2346
Installation…2346
Monitor…2347
Removal…2347
Installation…2348
Pump Controller…2349
Removal…2349
Installation…2350
Engine Controller…2352
Removal…2352
Installation…2352
60 AIR CONDITIONER…2353
STRUCTURE AND FUNCTION…2356
Air Conditioner Component…2356
Configuration and Function of Refrigerating cycle…2358
Outline of Refrigerating Cycle…2359
Air Conditioner Unit…2362
Functions of Major Components in the Air Conditioner Unit…2364
Control Plate…2366
Compressor…2369
Condenser and Receiver Drier…2370
TESTING AND ADJUSTING…2371
Caution About Refrigerant…2371
Troubleshooting Procedure…2372
Block Diagram…2373
Circuit Diagram and Arrangement of Connector Pins…2374
Detail of Air Conditioner Unit…2376
Part and Connector Locations…2378
Testing Air Leakage (Ducts)…2382
Testing with Self-diagnosis Function…2384
Testing Temperature Control…2387
Testing Vent (Mode) Changeover…2390
Testing Recirc/Fresh Changeover…2394
Testing Inner Sensor…2396
Testing Evaporator Temperature Sensor…2397
Testing Sunlight Sensor…2399
Testing (Dual) Pressure Switch for Refrigerant…2400
Testing Relays…2402
TROUBLESHOOTING…2404
Troubleshooting Chart 1…2404
Troubleshooting Chart 2…2405
Troubleshooting for Electrical System (E mode)…2408
E-1 Power Supply System (Air Conditioner does not Operate)…2409
E-2 Compressor System (Air is Not Cooled)…2413
E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)…2416
E-4 Temperature Cannot be Controlled…2420
E-5 Vent (Mode) Cannot be Changed Over…2423
E-6 Recirc/Fresh Air Cannot be Changed Over…2426
Troubleshooting With Gauge Pressure…2429
Connection of Service Tool…2432
Precautions for connecting air conditioner piping…2434
Handling of Compressor Oil…2435
Control of Compressor Oil…2435
Adding of Compressor Oil…2435
Compressor Replacement…2436
Applying Compressor Oil for O-ring…2436
Desiccant Replacement Procedure…2437
90 DIAGRAMS AND DRAWINGS…2439
HYDRAULIC DIAGRAM – PC300LC/HD-8…2441
ELECTRICAL SYSTEM…2442
Electrical Circuit Diagram (1/5)…2442
Electrical Circuit Diagram (2/5)…2443
Electrical Circuit Diagram (3/5)…2444
Electrical Circuit Diagram (4/5)…2445
Electrical Circuit Diagram (5/5)…2446
Connector Arrangement Diagram – PC300LC/HD-8…2447
CEBM3006C2 – Hydraulic Excavator PC300LC-6, PC300HD-6 Shop Manual…2448
CONTENTS…2449
00 SAFETY/FOREWARD…2456
01 GENERAL…2471
SPECIFICATION DRAWINGS…2472
PC300LC-6…2472
PC300HD-6…2474
SPECIFICATIONS…2476
PC300LC-6…2476
PC300HD-6…2476
WEIGHT TABLE…2478
PC300LC-6…2478
PC300HD-6…2478
FUEL, COOLANT AND LUBRICANTS…2480
PC300LC-6…2480
PC300HD-6…2481
ENGINE OIL SPECIFICATIONS…2482
DIESEL FUEL SPECIFICATIONS…2483
COOLANT SPECIFICATIONS…2484
10 STRUCTURE AND FUNCTION …2490
ENGINE RELATED PARTS …2491
RADIATOR OIL COOLER …2493
POWER TRAIN …2494
FINAL DRIVE PC300LC-6…2495
FINAL DRIVE PC300HD-6…2496
SWING CIRCLE …2497
SWING MACHINERY …2498
TRACK FRAME RECOIL SPRING …2499
TRACK SHOE …2501
HYDRAULIC PIPING DRAWING …2502
HYDRAULIC CIRCUIT DIAGRAM …2503
HYDRAULIC TANK…2504
HYDRAULIC PUMP …2505
CONTROL PUMP…2524
SUCTION SAFETY VALVE …2535
CLSS …2536
SWING MOTOR …2578
CENTER SWIVEL JOINT …2582
TRAVEL MOTOR …2583
VALVE CONTROL …2598
WORK EQUIPMENT SWING PPC VALVE …2599
TRAVEL PPC VALVE …2603
SERVICE PPC VALVE …2607
PPC SAFETY LOCK VALVE…2610
PPC ACCUMULATOR…2610
PPC SHUTTLE VALVE TRAVEL JUNCTION VALVE …2611
EPC SOLENOID VALVE …2618
FOR LS SELECT, BOOM HI 2-STAGE SAFETY VALVE, MERGE/FLOW DIVIDER, TRAVEL SPEED, SWING BRAKE…2618
FOR LS VALVE CONTROL…2620
BOOM HOLDING VALVE …2623
HYDRAULIC CYLINDER …2626
WORK EQUIPMENT …2627
ELECTRICAL WIRING DIAGRAM …2628
ELECTRICAL CIRCUIT DIAGRAM…2630
ENGINE CONTROL …2633
ELECTRONIC CONTROL SYSTEM …2639
MACHINE MONITOR SYSTEM…2662
20 TESTING AND ADJUSTMENT…2669
STANDARD VALUE TABLE FOR ENGINE…2670
STANDARD VALUE TABLE FOR CHASSIS PARTS…2671
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…2679
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…2687
MEASURING ENGINE SPEED…2688
MEASURING INTAKE MANIFOLD PRESSURE…2689
MEASURING INTAKE AIR RESTRICTION…2690
MEASURING LUBRICATING OIL PRESSURE…2691
MEASURING FUEL (FILTER) INLET RESTRICTION…2692
MEASURING BLOWBY PRESSURE…2693
MEASURING ENGINE BACK PRESSURE…2694
MEASURING EXHAUST COLOR…2695
MEASURING COOLANT TEMPERATURE…2696
MEASURING VALVE CLEARANCE…2697
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE…2698
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…2699
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)…2702
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…2704
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE…2707
TESTING SOLENOID VALVE OUTPUT PRESSURE…2709
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE…2711
ADJUSTING WORK EQUIPMENT SWING PPC VALVE…2713
TESTING TRAVEL DEVIATION…2714
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…2715
MEASURING OIL LEAKAGE…2717
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…2719
TESTING CLEARANCE OF SWING CIRCLE BEARING…2720
TESTING AND ADJUSTING TRACK SHOE TENSION…2721
BLEEDING AIR…2722
TROUBLESHOOTING…2724
TROUBLESHOOTING…2724
POINTS TO REMEMBER WHEN TROUBLESHOOTING …2725
SEQUENCE OF EVENTS IN TROUBLESHOOTING …2726
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE …2727
CHECKS BEFORE TROUBLESHOOTING …2736
CONNECTOR TYPES AND MOUNTING LOCATIONS …2737
CONNECTOR ARRANGEMENT DIAGRAM…2739
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…2741
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM …2752
DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL …2753
METHOD OF USING JUDGEMENT TABLE …2761
METHOD OF USING TROUBLSHOOTING CHARTS …2763
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE …2765
SERVICE CODE TABLE …2770
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)…2771
N-1 [E218] Communication abnormality…2772
TROUBLESHOOTING OF GOVERNOR PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (N MODE)…2774
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM…2775
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2776
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND RELATED PARTS…2780
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM…2782
E-1 Abnormality in governor, pump controller power source (controller LED is OFF)…2784
E-2 [E308] Abnormality in fuel control dial input value is displayed…2785
E-3 [317] Abnormality (disconnection) in motor drive system is displayed…2786
E-4 [318] Abnormality (short circuit) in motor drive system is displayed…2787
E-5 [E306] Abnormality in feedback potentiometer system is displayed…2788
E-6 [E315] Abnormality (short circuit) in battery relay output system is displayed…2789
E-7 [E316] Abnormality (step-out) in motor displayed…2790
E-8 Engine does not start…2791
E-9 Engine speed is irregular…2793
E-10 Lack of output (engine high idling speed is to low)…2797
E-11 Engine does not stop…2799
E-12 Defective operation of battery relay system (engine does not stop)…2801
TROUBLESHOOTING OF ENGINE SYSTEM…2803
METHOD OF USING TROUBLESHOOTING CHARTS…2804
S-1 Starting performance is poor (starting always takes time)…2808
S-2 Engine does not start…2809
S-3 Engine does not pick up smoothly (follow up is poor)…2812
S-4 Engine stops during operations…2813
S-5 Engine does not rotate smoothly (hunting)…2814
S-6 Engine lacks output (no power)…2815
S-7 Engine smoke is black (incomplete combustion)…2816
S-8 Oil consumption is excessive (or exhaust smoke is blue)…2817
S-9 Oil becomes contaminated quickly…2818
S-10 Fuel consumption is excessive…2819
S-11 Oil is in cooling water, or water spurts back, or water level goes down…2820
S-12 Oil pressure caution lamp lights up (drop in oil pressure)…2821
S-13 Oil level rises (water, fuel in oil)…2822
S-14 Water temperature becomes too high (overheating)…2823
S-15 Abnormal noise is made…2824
S-16 Vibration is excessive…2825
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)…2826
POINT TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…2827
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2828
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS…2834
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE…2836
C-1 Abnormality in controller power source system (controller LED is OFF)…2838
C-2 [E232] Short circuit in front pump TVC solenoid system is displayed…2839
C-3 [E233] Disconnection in front pump TVC solenoid system is displayed…2841
C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed…2843
C-5 [E237] Disconnection in rear pump WC solenoid system is displayed…2845
C-6 [E202] Short circuit in LS select solenoid system is displayed…2847
C-7 [E212] Disconnection in LS select solenoid system is displayed…2848
C-8 [E203] Short circuit in swing brake solenoid system is displayed…2849
C-9 [E213] Disconnection in swing brake solenoid system is displayed…2851
C-10 [E204] Short circuit in pump merge/divider solenoid system is displayed…2853
C-11 [E214] Disconnection in pump merge/divider solenoid system is displayed…2854
C-12 [E206] Short circuit in travel speed solenoid system is displayed…2855
C-13 [E216] Disconnection in travel speed selector solenoid system is displayed…2856
C-14 [E217] Model selection input error is displayed …2857
C-15 [E222] Short circuit in LS-EPC solenoid system is displayed…2859
C-16 [E223] Disconnection in LS-EPC solenoid system is displayed…2860
C-17 [E224] Abnormality in front pump pressure sensor system is displayed…2861
C-18 [E225] Abnormality in rear pump pressure sensor system is displayed…2862
C-19 [E226] Abnormality in pressure sensor power source system is displayed…2863
C-20 [E227] Abnormality in engine speed sensor system is displayed…2864
C-21 Abnormality in machine push up solenoid system (no service code displayed)…2865
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…2880
PUMP MERGE/DIVIDER LOGIC…2881
LS SELECT LOGIC…2882
SOLENOID ACTUATION TABLE…2882
TABLE OF FAILURE MODES AND CAUSES…2883
H-1 Speeds of all work equipment, swing, travel are slow or lack power…2887
H-2 There is excessive drop in engine speed, or engine stalls…2889
H-3 No work equipment, travel, swing move…2890
H-4 Abnormal noise generated (around pump)…2890
H-5 Auto-deceleration does not work (when PPC shuttle valve is cause)…2891
H-6 Fine control ability is poor or response is poor…2892
H-7 Boom is slow or lacks power…2893
H-8 Arm is slow or lacks power…2895
H-9 Bucket is slow or lacks power…2897
H-10 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)…2898
H-11 Excessive hydraulic drift (boom, arm, bucket)…2898
H-12 Excessive time lag (engine at low idling)…2899
H-13 Other equipment moves when single circuit is relieved…2899
H-14 In L/O, F/O modes, work equipment speed is faster than specified speed…2900
H-15 Defective actuation of machine push-up function…2900
H-16 In compound operations, work equipment with larger load is slow…2900
H-17 In swing + boom RAISE, boom RAISE is slow…2901
H-18 In swing + arm, arm is slow…2901
H-19 In swing + travel, travel speed drops excessively…2901
H-20 Travel deviation…2902
H-21 Travel speed is slow…2903
H-22 Steering does not turn easily or lacks power…2905
H-23 Travel speed does not switch or is faster than specified speed…2907
H-24 Travel speed does not switch or is faster than specified speed…2907
H-25 Does not swing…2908
H-26 Swing acceleration is poor or swing speed is slow…2909
H-27 Excessive overrun when stopping swing…2911
H-28 Excessive shock when stopping swing (one direction only)…2912
H-29 Excessive abnormal noise when stopping swing…2912
H-30 Excessive hydraulic drift of swing…2913
H-31 Swing speed is faster than specified swing speed…2914
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)…2867
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE…2868
F-1 Bit pattern 20-(l) Swing oil pressure switch does not light up…2870
F-2 Bit pattern 2042) Travel oil pressure switch does not light up…2871
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up…2872
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up…2873
F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up…2874
F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up…2875
F-7 Bit pattern 21-(l) Bucket CURL oil pressure switch does not light up…2876
F-8 Bit pattern 2142) Bucket DUMP oil pressure switch does not light up…2877
F-9 Bit pattern 2%(3) Swing lock switch does not light up…2878
F-11 Bit pattern 22-(6) L.H. knob switch does not light up…2879
TROUBLESHOOTING OF HYDRAULIC, MONITOR SYSTEM (M MODE)…2915
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2917
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE…2919
M-1 [E101] Abnormality in error data is displayed [E101] Error in clock data is displayed…2922
M-2 [E103] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed…2923
M-3 [E104] Air cleaner clogging detected is displayed…2924
M-4 [E106] Drop in engine oil Hi pressure detected is displayed…2924
M-5 [E108] Engine water temperature 105°C detected is displayed…2925
M-6 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds…2926
M-7 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out…2928
M-8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine (model)…2928
M-9 When starting switch is turned ON (engine stopped), basic check items flashes…2929
M-10 Preheating is not used but (preheating monitor) lights up…2932
M-11 When starting switch is turned ON and engine is started, basic check items flash…2933
M-12 When starting switch is turned ON (engine speed), caution items, emergency items flash…2935
M-13 When starting switch is turned ON and engine is started, caution items, emergency items flash…2937
M-14 When staring switch is turned ON (engine stopped), buzzer doesn't sound for 1 second Caution item flashes but doesn't sound…2940
M-15 No abnormality is displayed on monitor but buzzer sounds…2940
M-16 Night light on monitor panel does not light up (liquid crystal display is normal)…2941
M-17 Coolant temperature gauge does not rise…2942
M-18 Coolant temperature gauge does not give any display (none of gauge lamps light up during operation)…2942
M-19 Fuel level gauge always displays FULL…2943
M-20 Fuel level gauge does not give display…2943
M-21 Swing lock switch is turned ON (LOCK) but (swing lock monitor) does not light up…2944
M-22 Swing prolix switch is turned ON (LOCK) but (swing lock monitor) does not flash…2944
M-23 Service meter does not advance while engine is running…2945
M-24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed…2945
M-25 Defective fuel level sensor system…2946
M-26 Defective coolant temperature sensor system…2947
M-27 Defective engine oil level sensor system…2948
M-28 Defective coolant level sensor system…2949
M-29 Defective hydraulic oil level sensor system…2950
M-30 Wiper does not work or switch is not being used but wiper is actuated…2951
30 DISASSEMBLY AND ASSEMBLY…2955
METHOD OF USING MANUAL …2957
PRECAUTIONS WHEN CARRYING OUT OPERATION …2959
SPECIAL TOOL LIST …2961
SKETCHES OF SPECIAL TOOLS …2969
STARTING MOTOR …2977
ALTERNATOR …2977
ENGINE OIL COOLER …2977
FUEL INJECTION PUMP …2977
WATER PUMP …2978
NOZZLE HOLDER …2978
TURBOCHARGER …2978
THERMOSTAT …2978
ENGINE FRONT SEAL …2979
CYLINDER HEAD …2979
GOVERNOR MOTOR…2980
REMOVAL OF GOVERNOR MOTOR …2980
INSTALLATION OF GOVERNOR MOTOR …2980
HYDRAULIC COOLER…2981
REMOVAL OF HYDRAULIC COOLER …2981
INSTALLATION OF HYDRAULIC COOLER …2981
RADIATOR, HYDRAULIC COOLER…2982
REMOVAL OF RADIATOR, HYDRAULIC COOLER …2982
INSTALLATION OF RADIATOR, HYDRAULIC COOLER …2983
ENGINE, MAIN PUMP…2984
REMOVAL OF ENGINE, MAIN PUMP …2984
INSTALLATION OF ENGINE, MAIN PUMP …2987
DAMPER…2988
REMOVAL OF DAMPER …2988
INSTALLATION OF DAMPER …2988
FUEL TANK…2989
REMOVAL OF FUEL TANK…2989
INSTALLATION OF FUEL TANK …2989
CENTER SWIVEL JOINT…2990
REMOVAL OF CENTER SWIVEL JOINT …2990
INSTALLATION OF CENTER JOINT …2990
DISASSEMBLY OF CENTER SWIVEL JOINT …2991
ASSEMBLY OF CENTER SWIVEL JOINT …2991
FINAL DRIVE – PC3OOLC…2992
REMOVAL OF FINAL DRIVE – PC3OOLC …2992
INSTALLATION OF FINAL DRIVE …2992
DISASSEMBLY OF FINAL DRIVE …2993
ASSEMBLY OF FINAL DRIVE …2997
FINAL DRIVE – PC300HD…3004
REMOVAL OF FINAL DRIVE – PC300HD …3004
INSTALLATION OF FINAL DRIVE …3004
DISASSEMBLY OF FINAL DRIVE …3005
ASSEMBLY OF FINAL DRIVE…3009
TRAVEL MOTOR – PC3OOLC…3016
DISASSEMBLY OF TRAVEL MOTOR – PC3OOLC …3016
ASSEMBLY OF TRAVEL MOTOR …3020
TRAVEL MOTOR – PC300HD…3029
DISASSEMBLY OF TRAVEL MOTOR – PC300HD …3029
ASSEMBLY OF TRAVEL MOTOR …3033
SPROCKET…3043
REMOVAL OF SPROCKET …3043
INSTALLATION OF SPROCKET …3043
SWING MOTOR…3044
REMOVAL OF SWING MOTOR …3044
INSTALLATION OF SWING MOTOR …3044
DISASSEMBLY OF SWING MOTOR …3045
ASSEMBLY OF SWING MOTOR …3047
SWING MACHINERY…3054
REMOVAL OF SWING MACHINERY …3054
INSTALLATION OF SWING MACHINERY …3054
DISASSEMBLY OF SWING MACHINERY …3054
ASSEMBLY OF SWING MACHINERY…3058
REVOLVING FRAME…3063
REMOVAL OF REVOLVING FRAME …3063
INSTALLATION OF REVOLVING FRAME …3064
SWING CIRCLE…3065
REMOVAL OF SWING CIRCLE …3065
INSTALLATION OF SWING CIRCLE …3065
IDLER, RECOIL SPRING…3066
REMOVAL OF IDLER, RECOIL SPRING …3066
INSTALLATION OF IDLER, RECOIL SPRING …3066
IDLER – PC3OOLC…3067
DISASSEMBLY OF IDLER – PC3OOLC …3067
ASSEMBLY OF IDLER …3068
IDLER – PC300HD…3070
DISASSEMBLY OF IDLER – PC300HD …3070
ASSEMBLY OF IDLER …3071
RECOIL SPRING…3073
DISASSEMBLY OF RECOIL SPRING …3073
ASSEMBLY OF RECOIL SPRING …3074
TRACK ROLLER…3075
REMOVAL OF TRACK ROLLER …3075
INSTALLATION OF TRACK ROLLER …3075
DISASSEMBLY OF TRACK ROLLER …3076
ASSEMBLY OF TRACK ROLLER …3077
CARRIER ROLLER…3079
REMOVAL OF CARRIER ROLLER …3079
INSTALLATION OF CARRIER ROLLER …3079
DISASSEMBLY OF CARRIER ROLLER …3080
ASSEMBLY OF CARRIER ROLLER …3081
TRACK SHOE…3084
REMOVAL OF TRACK SHOE …3084
INSTALLATION OF TRACK SHOE …3084
HYDRAULIC TANK…3085
REMOVAL OF HYDRAULIC TANK …3085
INSTALLATION OF HYDRAULIC TANK …3086
CONTROL PUMP…3087
REMOVAL OF CONTROL PUMP …3087
INSTALLATION OF CONTROL PUMP …3087
MAIN PUMP…3088
REMOVAL OF MAIN PUMP …3088
INSTALLATION OF MAIN PUMP …3089
DISASSEMBLY OF MAIN PUMP …3090
ASSEMBLY OF MAIN PUMP …3096
CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, ROCKER CAM AND CRADLE, VALVE PLATE AND END CAP …3105
MAIN PUMP INPUT SHAFT OIL SEAL…3107
REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL …3107
INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL …3107
CONTROL VALVE…3108
REMOVAL OF CONTROL VALVE …3108
INSTALLATION OF CONTROL VALVE …3110
DISASSEMBLY OF CONTROL VALVE …3111
ASSEMBLY OF CONTROL VALVE …3114
PUMP MERGE/DIVIDER VALVE…3118
DISASSEMBLY OF PUMP MERGE/DIVIDER VALVE …3118
ASSEMBLY OF PUMP MERGE/DIVIDER VALVE …3118
PRESSURE COMPENSATION VALVE…3119
DISASSEMBLY OF PRESSURE COMPENSATION VALVE …3119
ASSEMBLY OF PRESSURE COMPENSATION VALVE …3119
SERVO VALVE FOR FRONT PUMP…3120
REMOVAL OF SERVO VALVE FOR FRONT PUMP …3120
INSTALLATION OF SERVO VALVE FOR FRONT PUMP …3120
SERVO VALVE FOR REAR PUMP…3121
REMOVAL OF SERVO VALVE FOR REAR PUMP …3121
INSTALLATION OF SERVO VALVE FOR REAR PUMP …3121
LS-EPC SOLENOID VALVE…3122
REMOVAL OF LS-EPC SOLENOID VALVE …3122
INSTALLATION OF LS-EPC SOLENOID VALVE …3122
SOLENOID VALVE…3123
REMOVAL OF SOLENOID VALVE …3123
INSTALLATION OF SOLENOID VALVE …3123
WORK EQUIPMENT PPC VALVE…3124
REMOVAL OF WORK EQUIPMENT PPC VALVE …3124
INSTALLATION OF WORK EQUIPMENT PPC VALVE …3124
WORK EQUIPMENT PPC VALVE…3125
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE …3125
ASSEMBLY OF WORK EQUIPMENT PPC VALVE …3125
TRAVEL PPC VALVE…3126
REMOVAL OF TRAVEL PPC VALVE …3126
INSTALLATION OF TRAVEL PPC VALVE …3126
DISASSEMBLY OF TRAVEL PPC VALVE …3127
ASSEMBLY OF TRAVEL PPC VALVE …3128
REMOVAL OF PPC SHUTTLE VALVE …3129
INSTALLATION OF PPC SHUTTLE VALVE …3130
DISASSEMBLY OF PPC SHUTTLE VALVE …3131
ASSEMBLY OF PPC SHUTTLE VALVE …3132
BOOM LOCK VALVE…3133
REMOVAL OF BOOM LOCK VALVE…3133
INSTALLATION OF BOOM LOCK VALVE …3133
DISASSEMBLY OF BOOM LOCK VALVE …3133
ASSEMBLY OF BOOM LOCK VALVE …3133
BOOM CYLINDER…3134
REMOVAL OF BOOM CYLINDER …3134
INSTALLATION OF BOOM CYLINDER …3135
ARM CYLINDER…3136
REMOVAL OF ARM CYLINDER …3136
INSTALLATION OF ARM CYLINDER …3137
BUCKET CYLINDER…3138
REMOVAL OF BUCKET CYLINDER …3138
INSTALLATION OF BOOM CYLINDER …3139
HYDRAULIC CYLINDER…3140
DISASSEMBLY OF HYDRAULIC CYLINDER …3140
ASSEMBLY OF HYDRAULIC CYLINDER…3142
WORK EQUIPMENT…3144
REMOVAL OF WORK EQUIPMENT …3144
INSTALLATION OF WORK EQUIPMENT …3145
BUCKET…3146
REMOVAL OF BUCKET …3146
INSTALLATION OF BUCKET …3147
ARM…3148
REMOVAL OF ARM …3148
INSTALLATION OF ARM …3149
BUCKET, ARM…3150
REMOVAL OF BUCKET, ARM …3150
INSTALLATION OF BUCKET, ARM …3151
BOOM…3152
REMOVAL OF BOOM …3152
INSTALLATION OF BOOM …3153
OPERATORS CAB…3154
REMOVAL OF OPERATORS CAB…3154
INSTALLATION OF OPERATORS CAB …3155
COUNTERWEIGHT…3156
REMOVAL OF COUNTERWEIGHT …3156
INSTALLATION OF COUNTERWEIGHT …3156
AIR CONDITIONER COMPRESSOR…3157
REMOVAL OF AIR CONDITIONER COMPRESSOR …3157
INSTALLATION OF AIR CONDITIONER COMPRESSOR …3157
CONDENSER…3158
REMOVAL OF CONDENSER …3158
INSTALLATION OF CONDENSER …3158
AIR CONDITIONER UNIT…3159
REMOVAL OF AIR CONDITIONER UNIT …3159
INSTALLATION OF AIR CONDITIONER UNIT …3160
GOVERNOR, PUMP CONTROLLER…3161
REMOVAL OF GOVERNOR, PUMP CONTROLLER …3161
INSTALLATION OF GOVERNOR, PUMP CONTROLLER …3161
MONITOR PANEL…3162
REMOVAL OF MONITOR PANEL…3162
INSTALLATION OF MONITOR PANEL …3162
CONTROL STAND CASE…3163
REMOVAL OF CONTROL STAND CASE …3163
INSTALLATION OF CONTROL STAND CASE …3164
40 MAINTENANCE STANDARD…3165
ENGINE MOUNT…3166
SWING MACHINERY …3167
SWING CIRCLE …3169
FINAL DRIVE (PC300LC-6)…3170
FINAL DRIVE (PC300HD-6)…3172
TRACK FRAME – RECOIL SPRING (PC300LC-6)…3174
TRACK FRAME – RECOIL SPRING (PC300HD-6)…3175
IDLER (PC300LC-6)…3176
IDLER (PC300HD-6)…3178
CARRIER ROLLER …3179
TRACK ROLLER…3180
TRACK CHAIN ASSM. (PC300LC-6)…3182
TRACK CHAIN ASSM. (PC300HD-6)…3183
HYDRAULIC PUMP …3184
CONTROL PUMP AND RELIEF VALVE …3185
CONTROL VALVE (10-SPOOL)…3186
SUCTION-SAFETY VALVE…3192
SWING MOTOR …3193
TRAVEL MOTOR (PC300LC-6)…3194
TRAVEL MOTOR (PC300HD-6)…3195
WORK EQUIPMENT – SWING PPC VALVE …3196
TRAVEL PPC VALVE …3197
SERVICE PPC VALVE …3198
PPC SHUTTLE VALVE – TRAVEL JUNCTION VALVE …3199
EPC – SOLENOID VALVE …3200
CENTER SWIVEL JOINT…3201
BOOM HOLDING VALVE…3202
HYDRAULIC CYLINDER …3203
WORK EQUIPMENT …3204
SEAM02070501 – Hydraulic Excavator PC300-5, PC300LC-5 Operation & Maintenance Manual…3211
FOREWORD…3213
CONTENTS…3215
OPERATION…3216
GENERAL LOCATIONS AND SPECIFICATIONS…3216
INSTRUMENTS AND CONTROLS…3218
METHOD OF USING MODE SELECTOR SWITCHES…3258
CHECK BEFORE STARTING…3262
OPERATING YOUR MACHINE…3268
INVERSION AND REPLACEMENT OF BUCKET…3290
HANDLING THE TRAPEZOIDAL BUCKET…3292
HANDLING THE CLAMSHELL BUCKET…3292
SELECTION OF TRACK SHOES…3294
SELECTION OF BUCKET TEETH…3296
TRANSPORTATION…3297
INSTALLATION OF OPTIONAL ELECTRICAL EQUIPMENT…3302
COLD WEATHER OPERATION…3304
MAINTENANCE…3313
PERIODIC MAINTENANCE…3313
PRECAUTIONS WHEN DISASSEMBLING MACHINE…3314
BLEEDING AIR FROM CIRCUIT…3316
PERIODICAL REPLACEMENT OF SAFETY PARTS…3320
MAINTENANCE TABLE…3324
OIL FILLER AND LEVEL GAUGE POSITIONS…3328
CHECK BEFORE STARTING…3330
EVERY 100 HOURS SERVICE…3330
INITIAL 250 HOURS SERVICE…3334
EVERY 250 HOURS SERVICE…3336
EVERY 500 HOURS SERVICE…3344
EVERY 1000 HOURS SERVICE…3348
EVERY 2000 HOURS SERVICE…3352
EVERY 4000 HOURS SERVICE…3357
WHEN REQUIRED…3358
ADJUSTMENT…3376
TROUBLE SHOOTING GUIDE…3378
SERVICE METER…3388
MACHINE AND ENGINE SERIAL NUMBERS…3390
FUEL, COOLANT AND LUBRICANTS…3392
SAFETY AND OPERATION…3395
CONTENTS…3397
SAFETY HINTS…3398
RADIO…3414
LOCKING CAP…3418
OPERATING THE CAR COOLER…3420
OPERATING THE AIR CONDITIONER…3424
EXCAVATOR’S WORK…3433
HANDLING OF BATTERY…3434
PRECAUTIONS FOR MAINTENANCE…3440
STORAGE…3446
COOLANT AND LUBRICANTS…3448
Komatsu PC300LC, PC300HD Hydraulic Excavators & Logging Excavator PC300LL Repair Service Manuals