Komatsu PC308USLC-3 Hydraulic Excavator Workshop Repair Manual, Operation Maintenance Manual, Parts Book PDF - MKMTSPC308USLC.zip
A full workshop service and repair guide, complete with Electrical Wiring Diagrams, covering the Komatsu Hydraulic Excavator PC308USLC-3. It contains every technical detail needed to service, troubleshoot, fix, and overhaul the machine the way expert technicians do.
This Komatsu PC308USLC-3 excavator workshop manual contains:
* 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.
PRODUCT DETAILS:
Total Pages: 1,143 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
NJPT007900 - Hydraulic Excavator PC308USLC-3 Operation & Maintenance Manual_Parts Book...2
SEBM033101 - Hydraulic Excavator PC308USLC-3 Shop Manual...268
COVER...268
CONTENTS...269
SAFETY ...274
SAFETY NOTICE...274
FOREWARD...276
GENERAL...276
HOW TO READ THE SHOP MANUAL...277
HOISTING INSTRUCTIONS...278
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...279
COATING MATERIALS...281
STANDARD TIGHTENING TORQUE...283
ELECTRIC WIRE CODE...286
CONVERSION TABLE...287
UNITS...293
01 GENERAL...294
SPECIFICATION DIMENSION DRAWINGS...295
SPECIFICATIONS...297
WEIGHT TABLE...299
FUEL, COOLANT, AND LUBRICANTS...301
10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD...302
ENGINE RELATED PARTS...303
RADIATOR * OIL COOLER * AFTERCOOLER...304
POWER TRAIN...305
FINAL DRIVE...307
SWING MACHINERY...309
SWING CIRCLE...311
TRACK FRAME * RECOIL SPRING...313
IDLER...315
CARRIER ROLLER...317
TRACK ROLLER...318
TRACK SHOE...319
HYDRAULIC TANK...323
HYDRAULIC PUMP...324
CONTROL VALVE...345
SELF PRESSURE REDUCING VALVE...361
CLSS...366
SWING MOTOR...367
REVERSE PREVENTION VALVE...372
CENTER SWIVEL JOINT...374
TRAVEL MOTOR...376
TRAVEL JUNCTION VALVE...386
TRAVEL PPC SHUTTLE VALVE...388
VALVE CONTROL...390
WORK EQUIPMENT * SWING PPC VALVE...391
TRAVEL PPC VALVE...395
SERVICE PPC VALVE...404
SOLENOID VALVE...407
PPC ACCUMULATOR...409
RETURN OIL FILTER...410
BOOM HYDRAULIC DRIFT PREVENTION VALVE...411
LIFT CHECK VALVE...414
ATTACHMENT CIRCUIT SELECTOR VALVE...415
HYDRAULIC CYLINDER...417
WORK EQUIPMENT...419
AIR CONDITIONER...425
ENGINE CONTROL...426
ELECTRONIC CONTROL SYSTEM...434
MONITORING SYSTEM...459
SENSOR...466
20 TESTING AND ADJUSTING...470
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...471
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...472
TESTING AND ADJUSTING...480
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...481
INSPECTION AND ADJUSTMENT OF ENGINE RPM...483
MEASUREMENT OF EXHAUST COLOR...485
ADJUSTMENT OF VALVE CLEARANCE...486
MEASUREMENT OF COMPRESSION PRESSURE...488
MEASUREMENT OF BLOW-BY PRESSURE...489
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING...490
MEASUREMENT OF ENGINE OIL PRESSURE...492
ADJUSTMENT OF ENGINE SPEED SENSOR...493
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION...493
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM...494
GOVERNOR MOTOR LEVER STROKE...495
HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...496
PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...499
LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE...501
CONTROL CIRCUIT OIL PRESSURE...504
MEASURING SOLENOID VALVE OUTPUT PRESSURE...505
MEASURING PPC VALVE OUTPUT PRESSURE...508
ADJUSTING WORK EQUIPMENT * SWING PPC VALVE...509
TESTING TRAVEL DEVIATION...510
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...511
MEASURING SWING, TRAVEL MOTOR OIL LEAKAGE...512
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...513
TESTING CLEARANCE OF SWING CIRCLE BEARING...514
TESTING WEAR OF SPROCKET...515
TESTING AND ADJUSTING TRACK SHOE TENSION...516
BLEEDING AIR...517
INSPECTION PROCEDURES FOR DIODE...519
TROUBLESHOOTING...520
POINTS TO REMEMBER WHEN TROUBLESHOOTING...521
SEQUENCE OF EVENTS WHEN TROUBLESHOOTING...522
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...523
CHECKS BEFORE TROUBLESHOOTING...531
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...532
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...537
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...549
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...571
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...572
METHOD OF USING JUDGEMENT TABLE...587
METHOD OF USING TROUBLESHOOTING CHARTS...589
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...591
TROUBLESHOOTING OF COMMUNICATIONS ABNORMALITY (N MODE)...596
N-1 [E218] COMMUNICATIONS ABNORMALITY...597
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED...598
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...601
SERVICE CODE IN ELECTRICAL SYSTEM [E101] (ABNORMAL DATA IN ERROR HISTORY)...603
SERVICE CODE IN ELECTRICAL SYSTEM [E112] (SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)...605
SERVICE CODE IN ELECTRICAL SYSTEM [E113] (SHORT CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)...607
SERVICE CODE IN ELECTRICAL SYSTEM [E114] (SHORT CIRCUITING IN WINDOW WASHER DRIVE SYSTEM)...609
SERVICE CODE IN ELECTRICAL SYSTEM [E115] (ABNORMAL WINDSHIELD WIPER MOTION)...611
SERVICE CODE IN ELECTRICAL SYSTEM [E116] (ABNORMALITY IN RETRACTING WINDSHIELD WIPER)...613
SERVICE CODE IN ELECTRICAL SYSTEM [E201] (SHORT CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)...615
SERVICE CODE IN ELECTRICAL SYSTEM [E203] (SHORT CIRCUITING IN SWING HOLDING BRAKE SOLENOID)...617
SERVICE CODE IN ELECTRICAL SYSTEM [E204] (SHORT CIRCUITING IN MERGE/DIVIDE SOLENOID)...619
SERVICE CODE IN ELECTRICAL SYSTEM [E205] (SHORT CIRCUITING IN 2 STAGE RELIEF SOLENOID)...621
SERVICE CODE IN ELECTRICAL SYSTEM [E206] (SHORT CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID)...623
SERVICE CODE IN ELECTRICAL SYSTEM [E211] (DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)...625
SERVICE CODE IN ELECTRICAL SYSTEM [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)...627
SERVICE CODE IN ELECTRICAL SYSTEM [E214] (DISCONNECTION OF MERGE/DIVIDE SOLENOID)...629
SERVICE CODE IN ELECTRICAL SYSTEM [E215] (DISCONNECTION IN 2 STAGE RELEIF SOLENOID)...631
SERVICE CODE IN ELECTRICAL SYSTEM [E216] (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)...633
SERVICE CODE IN ELECTRICAL SYSTEM [E217] (ABNORMALITY IN INPUTTING MODEL CODE)...635
SERVICE CODE IN ELECTRICAL SYSTEM [E218] (DISCONNECTION OF S NET SIGNAL)...637
SERVICE CODE IN ELECTRICAL SYSTEM [E222] (SHORT CIRCUITING IN LS-EPC SOLENOID)...639
SERVICE CODE IN ELECTRICAL SYSTEM [E223] (DISCONNECTION IN LS-EPC SOLENOID SYSTEM)...640
SERVICE CODE IN ELECTRICAL SYSTEM [E224] (ABNORMALITY IN F PUMP PRESSURE SENSOR)...641
SERVICE CODE IN ELECTRICAL SYSTEM [E225] (ABNORMALITY IN R PUMP PRESSURE SENSOR)...643
SERVICE CODE IN ELECTRICAL SYSTEM [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE)...645
SERVICE CODE IN ELECTRICAL SYSTEM [E227] (ABNORMALITY IN ENGINE ROTATION SENSOR)...647
SERVICE CODE IN ELECTRICAL SYSTEM [E228] (SHORT CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)...648
SERVICE CODE IN ELECTRICAL SYSTEM [E232] (SHORT CIRCUITING IN PC-EPC SOLENOID)...649
SERVICE CODE IN ELECTRICAL SYSTEM [E233] (DISCONNECTION IN PC-EPC SOLENOID SYSTEM)...651
SERVICE CODE IN ELECTRICAL SYSTEM [E238] (DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY)...653
SERVICE CODE IN ELECTRICAL SYSTEM [E256] (INCORRECT NONVOLATILE MEMORY DATA)...655
SERVICE CODE IN ELECTRICAL SYSTEM [E306] (ABNORMALITY IN GOVERNOR POTENTIOMETER)...657
SERVICE CODE IN ELECTRICAL SYSTEM [E308] (ABNORMALITY IN FUEL DIAL)...659
SERVICE CODE IN ELECTRICAL SYSTEM [E315] (SHORT CIRCUITING IN BATTERY RELAY)...661
SERVICE CODE IN ELECTRICAL SYSTEM [E316] (STEP OUT IN GOVERNOR MOTOR)...663
SERVICE CODE IN ELECTRICAL SYSTEM [E317] (DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B)...665
SERVICE CODE IN ELECTRICAL SYSTEM [E318] (SHORT CIRCUITING IN GOVERNOR MOTOR PHASE A AND PHASE B)...667
SERVICE CODE IN ELECTRICAL SYSTEM [E501] ("MODEL SELECTION" FUNCTION NOT PROVIDED YET)...669
SERVICE CODE IN ELECTRICAL SYSTEM [E502] (MODEL SELECTING SIGNAL FAULT)...670
FAILURE CODE IN MECHANICAL SYSTEM [E104] (AIR CLEANER CLOGGING)...671
FAILURE CODE IN MECHANICAL SYSTEM [E108] (ENGINE COOLING WATER OVERHEATING)...672
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...674
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...675
E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)...676
E-2 ENGINE STOPS WHILE IN OPERATION...679
E-3 ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING...681
E-4 ENGINE DOES NOT STOP...683
E-5 AUTO-DECELERATOR DOES NOT WORK...685
E-6 AUTO ENGINE WARM UP DEVICE DOES NOT WORK...686
E-7 PREHEATER DOES NOT WORK...687
E-8 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE...689
E-9 ONE TOUCH POWER MAX SWITCH DOES NOT WORK...691
E-10 NO DISPLAY IN MONITOR PANEL AT ALL...692
E-11 PART OF DISPLAY ON MONITOR PANEL IS MISSING...693
E-12 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL...693
E-13 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING...694
E-14 ENGINE COOLING TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY...695
E-15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY...696
E-16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY...697
E-17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY...699
E-18 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS...701
E-19 WINDSHIELD WIPER DOES NOT WORK...703
E-20 ALARMING BUZZER CANNOT BE CANCELLED...705
E-21 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...706
E-22 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...707
E-23 "ARM DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...708
E-24 "ARM DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...709
E-25 "BUCKET DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...710
E-26 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...711
E-27 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...713
E-28 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...715
E-29 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...717
E-30 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...719
E-31 AIR CONDITIONER DOES NOT WORK...721
E-32 TRAVEL ALARM DOES NOT SOUND...722
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...724
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS...725
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...727
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW...728
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS...729
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE...730
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...730
H-5 AUTO-DECELERATOR DOES NOT WORK...731
H-6 FINE CONTROL MODE DOES NOT FUNCTION...731
H-7 BOOM MOVES SLOWLY OR LACKS POWER...732
H-8 ARM MOVES SLOWLY OR LACKS POWER...733
H-9 BUCKET MOVES SLOWLY OR LACKS POWER...734
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION...734
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT...735
H-12 WORK EQUIPMENT HAS A BIG TIME LAG...736
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT...736
H-14 ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE...736
H-15 IN COMOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY...737
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY...737
H-17 IN SWING + TRAVEL, TRAEL SPEED DROPS SHARPLY...737
H-18 MACHINE SWERVES IN TRAVEL...738
H-19 MACHINE TRAVELS SLOWLY...739
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER...740
H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST...741
H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)...742
H-23 MACHINE DOES NOT SWING...743
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW...744
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING...745
H-26 THERE IS A BIG SHOCK WHEN STOPPING SWING...746
H-27 THERE IS A BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING...746
TROUBLESHOOTING OF ENGINE (S MODE)...747
METHOD OF USING TROUBLESHOOTING CHARTS...748
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...752
S-2 ENGINE DOES NOT START...754
(1) ENGINE DOES NOT TURN...754
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...755
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...756
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)...757
S-4 ENGINE STOPS DURING OPERATIONS...758
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...759
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...760
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...761
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...762
S-9 OIL BECOMES CONTAMINATED QUICKLY...763
S-10 FUEL CONSUMPTION IS EXCESSIVE...764
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...765
S-12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE)...766
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...767
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...768
S-15 ABNORMAL NOISE IS MADE...769
S-16 VIBRATION IS EXCESSIVE...770
30 DISASSEMBLY AND ASSEMBLY...771
METHOD OF USING MANUAL...773
PRECAUTIONS WHEN CARRYING OUT OPERATION...775
SPECIAL TOOL LIST...778
REMOVAL OF ENGINE ASSEMBLY...781
INSTALLATION OF ENGINE ASSEMBLY...783
REMOVAL OF ENGINE FRONT SEAL...784
INSTALLATION OF ENGINE FRONT SEAL...785
REMOVAL OF ENGINE REAR SEAL...786
INSTALLATION OF ENGINE REAR SEAL...787
REMOVAL OF RADIATOR ASSEMBLY...788
INSTALLATION OF RADIATOR ASSEMBLY...789
REMOVAL OF HYDRAULIC OIL COOLER ASSEMBLY...790
INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...791
REMOVAL OF AFTERCOOLER ASSEMBLY...792
INSTALLATION OF AFTERCOOLER ASSEMBLY...792
REMOVAL OF FUEL TANK ASSEMBLY...793
INSTALLATION OF FUEL TANK ASSEMBLY...793
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY...794
DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY...795
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY...795
REMOVAL OF FINAL DRIVE ASSEMBLY...796
INSTALLATION OF FINAL DRIVE ASSEMBLY...796
DISASSEMBLY OF FINAL DRIVE ASSEMBLY...797
ASSEMBLY OF FINAL DRIVE ASSEMBLY...800
REMOVAL OF REVOLVING FRAME ASSEMBLY...806
INSTALLATION OF REVOLVING FRAME ASSEMBLY...806
REMOVAL OF SWING CIRCLE ASSEMBLY...807
INSTALLATION OF SWING CIRCLE ASSEMBLY...807
DISASSEMBLY OF RECOIL SPRING ASSEMBLY...808
ASSEMBLY OF RECOIL SPRING ASSEMBLY...809
REMOVAL OF SPROCKET...810
INSTALLATION OF SPROCKET...810
ASSEMBLY OF IDLER ASSEMBLY...811
ASSEMBLY OF TRACK ROLLER ASSEMBLY...813
EXPANSION OF TRACK SHOE ASSEMBLY...814
INSTALLATION OF TRACK SHOE ASSEMBLY...814
REMOVAL OF HYDRAULIC PUMP ASSEMBLY...815
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY...816
REMOVAL OF OIL SEAL IN HYRAULIC PUMP INPUT SHAFT...817
INSTALLATION OF OIL SEAL IN HYRAULIC PUMP INPUT SHAFT...817
REMOVAL OF CONTROL VALVE ASSEMBLY...818
INSTALLATION OF CONTROL VALVE ASSEMBLY...820
DISASSEMBLY OF CONTROL VALVE ASSEMBLY...821
ASSEMBLY OF CONTROL VALVE ASSEMBLY...823
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY...824
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...825
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...825