Komatsu PC300 PC300LC PC350 PC350LC PC350HD PC350LCD PC350NLC PC350NLCD Excavator Workshop Repair & Operation Maintenance Manual PDF - MKMTSPC300PC350OPMK.zip
An all-inclusive service and repair manual featuring Electrical Wiring Diagrams for the Komatsu Hydraulic Excavator PC300, PC300LC, PC350, PC350LC, PC350HD, PC350LCD, PC350NLC, and PC350NLCD Series — supplying every technical detail needed to service, troubleshoot, overhaul, and rebuild these machines the way professional technicians do.
Covering the Komatsu Hydraulic Excavator models PC300-6, PC300LC-6, PC350-6, PC350LC-6, PC300-7, PC300LC-7, PC350-7, PC350LC-7, PC300-8, PC300LC-8, PC350-8, PC350LC-8, PC350HD-8, PC350LCD-8, PC350NLC-8, and PC350NLCD-8, this workshop service repair 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: 11,450 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
00 INDEX AND FOREWORD...0
INDEX...3
COMPOSITION OF SHOP MANUAL...4
TABLE OF CONTENTS...6
FOREWORD AND GENERAL INFORMATION...15
SAFETY NOTICE...16
HOW TO READ THE SHOP MANUAL...21
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...23
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT...25
HANDLING OF CONNECTORS NEWLY USED FOR ENGINES...34
HOW TO READ ELECTRIC WIRE CODE...37
PRECAUTIONS WHEN CARRYING OUT OPERATION...40
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER...43
STANDARD TIGHTENING TORQUE TABLE...46
CONVERSION TABLE...50
01 SPECIFICATION...0
SPECIFICATION AND TECHNICAL DATA...57
SPECIFICATION DIMENSION DRAWINGS...58
SPECIFICATIONS...60
WEIGHT TABLE...66
TABLE OF FUEL, COOLANT AND LUBRICANTS...68
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...0
ENGINE AND COOLING SYSTEM...71
ENGINE RELATED PARTS...72
RADIATOR, OIL COOLER AND AFTERCOOLER...73
POWER TRAIN...75
POWER TRAIN...76
SWING CIRCLE...77
SWING MACHINERY...78
FINAL DRIVE...80
SPROCKET...82
UNDERCARRIAGE AND FRAME...85
TRACK FRAME AND RECOIL SPRING...86
IDLER...88
CARRIER ROLLER...90
TRACK ROLLER...91
TRACK SHOE...92
HYDRAULIC SYSTEM, PART 1...97
HYDRAULIC EQUIPMENT LAYOUT DRAWING...98
HYDRAULIC TANK AND FILTER...100
HYDRAULIC PUMP...102
HYDRAULIC SYSTEM, PART 2...127
CONTROL VALVE...128
CLSS...140
FUNCTIONS AND OPERATION BY VALVE...144
MERGE-DIVIDER VALVE...159
ATTACHMENT CIRCUIT SELECTOR VALVE...184
HYDRAULIC DRIFT PREVENTION VALVE...186
HYDRAULIC SYSTEM, PART 3...193
VALVE CONTROL...194
PPC VALVE...196
SOLENOID VALVE...218
PPC ACCUMULATOR...220
RETURN OIL FILTER...221
CENTER SWIVEL JOINT...222
TRAVEL MOTOR...223
SWING MOTOR...235
HYDRAULIC CYLINDER...244
WORK EQUIPMENT...247
WORK EQUIPMENT...248
DIMENSIONS OF COMPONENTS...250
CAB AND ITS ATTACHMENTS...255
AIR CONDITIONER PIPING...256
ELECTRICAL SYSTEM...259
ENGINE CONTROL...260
ELECTRONIC CONTROL SYSTEM...269
MONITOR SYSTEM...294
SENSOR...321
KOMTRAX TERMINAL SYSTEM...324
20 STANDARD VALUE TABLE...0
STANDARD SERVICE VALUE TABLE ...327
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...328
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...329
30 TESTING AND ADJUSTING...0
TESTING AND ADJUSTING, PART 1 ...341
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...343
MEASURING ENGINE SPEED...347
MEASURING AIR BOOST PRESSURE...348
MEASURING EXHAUST GAS COLOR ...349
ADJUSTING VALVE CLEARANCE ...351
MEASURING COMPRESSION PRESSURE...353
MEASURING BLOW-BY PRESSURE...357
MEASURING ENGINE OIL PRESSURE...358
MEASURING FUEL PRESSURE...359
HANDLING DURING CYLINDER CUT-OUT OPERATION ...363
HANDLING DURING NO INJECTION CRANKING OPERATION ...363
MEASURING FUEL RETURN RATE AND LEAKAGE...364
BLEEDING AIR FROM FUEL CIRCUIT ...366
CHECKING FUEL CIRCUIT FOR LEAKAGE...367
TESTING AND ADJUSTING AIR COMPRESSOR BELT TENSION ...368
MEASURING CLEARANCE IN SWING CIRCLE BEARINGS...369
TESTING AND ADJUSTING TRACK SHOE TENSION...370
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT...371
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE...375
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE...376
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE ...379
MEASURING SOLENOID VALVE OUTPUT PRESSURE...384
MEASURING PPC VALVE OUTPUT PRESSURE ...388
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES...389
INSPECTING LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT ...390
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ...392
MEASURING OIL LEAKAGE AMOUNT ...392
BLEEDING AIR FROM VARIOUS PARTS ...395
DIODE INSPECTION PROCEDURES...397
TESTING AND ADJUSTING, PART 2 ...399
SPECIAL FUNCTIONS OF MACHINE MONITOR...400
TESTING AND ADJUSTING, PART 3 ...457
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...458
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM...459
PROCEDURE FOR TESTING DIODES...463
PM CLINIC SERVICE...464
40 TROUBLESHOOTING...0
FAILURE CODE TABLE AND FUSE LOCATIONS...471
FAILURE CODES TABLE...472
FUSE LOCATIONS ...475
GENERAL INFORMATION ON TROUBLESHOOTING ...481
POINTS TO REMEMBER WHEN TROUBLESHOOTING...482
SEQUENCE OF EVENTS IN TROUBLESHOOTING ...483
CHECKS BEFORE TROUBLESHOOTING...484
CLASSIFICATION AND TROUBLESHOOTING STEPS...485
INFORMATION IN TROUBLESHOOTING TABLE...486
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...491
T-ADAPTER BOX AND T-ADAPTER TABLE...525
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1 ...529
FAILURE CODE [A000N1] ENG. HI OUT OF STD...531
FAILURE CODE [AA10NX] AIR CLEANER CLOGGING...532
FAILURE CODE [AB00KE] CHARGE VOLTAGE LOW...534
FAILURE CODE [B@BAZG] ENG OIL PRESS. LOW...536
FAILURE CODE [B@BAZK] ENG OIL LEVEL LOW ...538
FAILURE CODE [B@BCNS] ENG. WATER OVERHEAT...540
FAILURE CODE [B@BCZK] ENG WATER LEVEL LOW...542
FAILURE CODE [B@HANS] HYDR OIL OVERHEAT ...544
FAILURE CODE [CA111] EMC CRITICAL INTERNAL FAILURE ...545
FAILURE CODE [CA115] ENG NE AND BKUP SPEED SENS ERROR...545
FAILURE CODE [CA122] CHG AIR PRESS SENSOR HIGH ERROR...546
FAILURE CODE [CA123] CHG AIR PRESS SENSOR LOW ERROR...548
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR...550
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR ...552
FAILURE CODE [CA144] COOLANT TEMP SENS HIGH ERROR...554
FAILURE CODE [CA145] COOLANT TEMP SENS LOW ERROR...556
FAILURE CODE [CA153] CHG AIR TEMP SENSOR HIGH ERROR...558
FAILURE CODE [CA154] CHG AIR TEMP SENSOR LOW ERROR...560
FAILURE CODE [CA187] SENS SUPPLY 2 VOLT LOW ERROR...562
FAILURE CODE [CA221] AMBIENT PRESS SENS HIGH ERROR...564
FAILURE CODE [CA222] AMBIENT PRESS SENS LOW ERROR...566
FAILURE CODE [CA227] SENS SUPPLY 2 VOLT HIGH ERROR ...568
FAILURE CODE [CA234] ENG OVERSPEED ...569
FAILURE CODE [CA238] NE SPEED SENS SUPPLY VOLT ERROR...570
FAILURE CODE [CA271] IMV/PCV1 SHORT ERROR...571
FAILURE CODE [CA272] IMV/PCV1 OPEN ERROR ...572
FAILURE CODE [CA322] INJ #1 OPEN/SHORT ERROR...574
FAILURE CODE [CA323] INJ #5 OPEN/SHORT ERROR...576
FAILURE CODE [CA324] INJ #3 OPEN/SHORT ERROR...578
FAILURE CODE [CA325] INJ #6 OPEN/SHORT ERROR ...580
FAILURE CODE [CA331] INJ #2 OPEN/SHORT ERROR ...582
FAILURE CODE [CA332] INJ #4 OPEN/SHORT ERROR...584
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2 ...587
FAILURE CODE [CA342] CALIBRATION CODE INCOMPATIBILITY...589
FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR...590
FAILURE CODE [CA352] SENS SUPPLY 1 VOLT LOW ERROR...592
FAILURE CODE [CA386] SENS SUPPLY 1 VOLT HIGH ERROR...594
FAILURE CODE [CA428] WATER IN FUEL SENSOR HIGH ERROR ...596
FAILURE CODE [CA429] WATER IN FUEL SENSOR LOW ERROR...598
FAILURE CODE [CA441] BATTERY VOLTAGE LOW ERROR...600
FAILURE CODE [CA442] BATTERY VOLTAGE HIGH ERROR...602
FAILURE CODE [CA449] RAIL PRESS VERY HIGH ERROR...604
FAILURE CODE [CA451] RAIL PRESS SENSOR HIGH ERROR...608
FAILURE CODE [CA452] RAIL PRESS SENSOR LOW ERROR...610
FAILURE CODE [CA553] RAIL PRESS HIGH ERROR...612
FAILURE CODE [CA559] RAIL PRESS LOW ERROR ...613
FAILURE CODE [CA689] ENG NE SPEED SENSOR ERROR...615
FAILURE CODE [CA731] ENG BKUP SPEED SENS PHASE ERROR ...617
FAILURE CODE [CA757] ALL PERSISTENT DATA LOST ERROR...618
FAILURE CODE [CA778] ENG BKUP SPEED SENSOR ERROR ...620
FAILURE CODE [CA1633] KOMNET DATALINK TIMEOUT ERROR...622
FAILURE CODE [CA2185] THROT SENS SUP VOLT HIGH ERROR ...624
FAILURE CODE [CA2186] THROT SENS SUP VOLT LOW ERROR...625
FAILURE CODE [CA2249] RAIL PRESS VERY LOW ERROR ...626
FAILURE CODE [CA2265] ELECTRIC LIFT PUMP HIGH ERROR ...628
FAILURE CODE [CA2266] ELECTRIC LIFT PUMP LOW ERROR...630
FAILURE CODE [CA2555] GRID HTR RELAY VOLT HIGH ERROR ...632
FAILURE CODE [CA2556] GRID HTR RELAY VOLT LOW ERROR ...634
FAILURE CODE [D110KB] BATTERY RELAY DRIVE S/C...636
FAILURE CODE [DA25KP] 5V SENSOR 1 POWER ABNORMALITY ...638
FAILURE CODE [DA2RMC] PUMP COMM. ABNORMALITY...642
FAILURE CODE [DA2SKQ] MODEL SELECTION ABNORMALITY...644
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3 ...647
FAILURE CODE [DAFRMC] CAN DISCON (MONITOR DETECTED) ...650
FAILURE CODE [DHPAMA] F PUMP PRESS SENSOR ABNORMALITY ...652
FAILURE CODE [DHPBMA] R PUMP PRESS SENSOR ABNORMALITY...654
FAILURE CODE [DHS3MA] ARM CURL PPC SEN. ABNORMALITY...656
FAILURE CODE [DHS4MA] BUCKET CURL PPC PRESS SENSOR ABNORMALITY ...658
FAILURE CODE [DW43KA] TRAVEL SPEED SOL. DISC...660
FAILURE CODE [DW43KB] TRAVEL SPEED SOL. S/C...662
FAILURE CODE [DW45KA] SWING BRAKE SOL. DISC. ...664
FAILURE CODE [DW45KB] SWING BRAKE SOL. S/C...668
FAILURE CODE [DW91KA] TRAVEL JUNCTION SOL. DISC...670
FAILURE CODE [DW91KB] TRAVEL JUNCTION SOL. S/C...672
FAILURE CODE [DWJ0KA] MERGE-DIVIDER SOL. DISC. ...674
FAILURE CODE [DWJ0KB] MERGE-DIVIDER SOL. S/C...676
FAILURE CODE [DWK0KA] 2-STAGE RELIEF SOL. DISC...678
FAILURE CODE [DWK0KB] 2-STAGE RELIEF SOL. S/C...680
FAILURE CODE [DXA0KA] PC-EPC SOL. DISC...682
FAILURE CODE [DXA0KB] PC-EPC SOL. S/C...684
FAILURE CODE [DXE0KA] LS-EPC SOL. DISC...686
FAILURE CODE [DXE0KB] LS-EPC SOL. S/C...688
FAILURE CODE [DXE4KA] SERVICE CURRENT EPC DISC...690
FAILURE CODE [DXE4KB] SERVICE CURRENT EPC S/C...691
FAILURE CODE [DY20KA] WIPER WORKING ABNORMALITY ...692
FAILURE CODE [DY20MA] WIPER PARKING ABNORMALITY ...694
FAILURE CODE [DY2CKB] WASHER DRIVE SHORT ...696
FAILURE CODE [DY2DKB] WIPER DRIVE (FOR) SHORT...698
FAILURE CODE [DY2EKB] WIPER DRIVE (REV) SHORT ...700
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ...703
BEFORE CARRYING OUT TROUBLESHOOTING OF ELECTRICAL SYSTEM...706
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...708
E-1 ENGINE DOES NOT START...709
E-2 AUTO-DECELERATOR DOES NOT OPERATE ...712
E-3 AUTOMATIC WARMING-UP SYSTEM DOES NOT OPERATE ...714
E-4 PREHEATER DOES NOT OPERATE ...716
E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE...718
E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE...720
E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL ...722
E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS...724
E-9 CONTENTS OF DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE...724
E-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUNNING...725
E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY ...726
E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...728
E-13 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY...729
E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY...730
E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTHING...732
E-16 WINDSHIELD WIPER AND WINDOW WASHER DO NOT OPERATE ...734
E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY ...738
E-18 MONITORING FUNCTION FAILS TO DISPLAY ? BOOM RAISE ? NORMALLY ...740
E-19 MONITORING FUNCTION FAILS TO DISPLAY ? BOOM LOWER ? NORMALLY ...742
E-20 MONITORING FUNCTION FAILS TO DISPLAY ? ARM IN ? NORMALLY ...744
E-21 MONITORING FUNCTION FAILS TO DISPLAY ? ARM OUT ? NORMALLY ...746
E-22 MONITORING FUNCTION FAILS TO DISPLAY ? BUCKET CURL ? NORMALLY ...748
E-23 MONITORING FUNCTION FAILS TO DISPLAY ? BUCKET DUMP ? NORMALLY ...750
E-24 MONITORING FUNCTION FAILS TO DISPLAY ? SWING ? NORMALLY...752
E-25 MONITORING FUNCTION FAILS TO DISPLAY ? TRAVEL ? NORMALLY ...754
E-26 MONITORING FUNCTION FAILS TO DISPLAY ? TRAVEL DIFFERENTIAL PRESSURE ? NORMALLY ...756
E-27 MONITORING FUNCTION FAILS TO DISPLAY ? SERVICE ? NORMALLY...758
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ...760
E-29 AIR CONDITIONER DOES NOT OPERATE...762
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING ...764
E-31 HORN DOES NOT SOUND...766
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ...769
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM ...772
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...774
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW...776
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS ...778
H-3 NO WORK EQUIPMENT, SWING OR TRAVEL MOVE...779
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...779
H-5 AUTO-DECELERATOR DOES NOT WORK...780
H-6 FINE CONTROL MODE DOES NOT FUNCTION OR RESPONDS SLOW ...780
H-7 BOOM MOVES SLOWLY OR LACKS POWER ...781
H-8 ARM MOVES SLOWLY OR LACKS POWER...782
H-9 BUCKET MOVES SLOWLY OR LACKS POWER...783
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION ...783
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT...784
H-12 WORK EQUIPMENT HAS BIG TIME LAG...786
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT...786
H-14 POWER MAX. SWITCH DOES NOT OPERATE...787
H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY ...787