Komatsu Logging Road Builder / Excavator PC350LL-E0, PC300-E0, PC300LC-E0, PC350-E0, PC350LC-E0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Logging Road Builder / Excavator PC350LL-7E0, PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Logging Road Builder / Excavator PC350LL-7E0, PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,412 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English / Spanish
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TEN00117-08 - Hydraulic Excavator PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0 Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
00 Index and foreword...0
Index...2
Composition of shop manual...3
Table of contents...5
Foreword and general information...14
Safety notice...15
How to read the shop manual...20
Explanation of terms for maintenance standard...22
Handling of electric equipment and hydraulic component...24
Handling of connectors newly used for engines...33
How to read electric wire code...36
Precautions when carrying out operation...39
Method of disassembling and connecting push-pull type coupler...42
Standard tightening torque table...45
Conversion table...49
01 Specification...0
Specification and technical data...56
Specification dimension drawings...57
Specifications...59
Weight table...65
Table of fuel, coolant and lubricants...67
10 Structure, function and maintenance standard...0
Engine and cooling system...70
Engine related parts...71
Radiator, oil cooler and aftercooler...72
Power train...74
Power train...75
Final drive...77
Sprocket...79
Swing machinery...81
Swing circle...83
Undercarriage and frame...86
Track frame and recoil spring...87
Idler...89
Carrier roller...91
Track roller...92
Track shoe...93
Hydraulic system, Part 1...98
Hydraulic equipment layout drawing...99
Hydraulic tank and filter...101
Hydraulic pump...103
Hydraulic system, Part 2...128
Control valve...129
CLSS...141
Functions and operation by valve...145
Merge-divider valve...160
Attachment circuit selector valve...185
Hydraulic drift prevention valve...187
Hydraulic system, Part 3...194
Valve control...195
PPC valve...196
Solenoid valve...212
PPC accumulator...214
Return oil filter...215
Center swivel joint...216
Travel motor...217
Swing motor...229
Hydraulic cylinder...238
Work equipment...242
Work equipment...243
Dimensions of components...245
Cab and its attachments...250
Air conditioner piping...251
Electrical system...254
Engine control...255
Electronic control system...264
Monitor system...289
Sensor...307
KOMTRAX system...310
20 Standard value table...0
Standard service value table...314
Standard value table for engine related parts...315
Standard value table for chassis related parts...316
30 Testing and adjusting...0
Testing and adjusting, Part 1...328
Tools for testing, adjusting and troubleshooting...330
Sketches of special tools...334
Measuring engine speed...335
Measuring air boost pressure...336
Measuring exhaust gas color...337
Adjusting valve clearance...339
Measuring compression pressure...341
Measuring blow-by pressure...345
Measuring engine oil pressure...346
Measuring fuel pressure...347
Handling during cylinder cut-out operation...352
Handling during no injection cranking operation...352
Measuring fuel return rate and leakage...353
Bleeding air from fuel circuit...355
Checking fuel circuit for leakage...356
Testing and adjusting air compressor belt tension...357
Replacement of fan belt...358
Replacement of alternator belt...359
Measuring clearance in swing circle bearings...360
Testing and adjusting track shoe tension...361
Testing and adjusting oil pressure in work equipment, swing and travel circuit...362
Testing and adjusting control circuit oil pressure...366
Testing and adjusting pump PC control circuit oil pressure...367
Testing and adjusting pump LS control circuit oil pressure...370
Measuring solenoid valve output pressure...375
Measuring PPC valve output pressure...379
Adjusting play of work equipment and swing PPC valves...380
Inspecting locations of hydraulic drift of work equipment...381
Releasing remaining pressure in hydraulic circuit...383
Measuring oil leakage amount...384
Bleeding air from various parts...386
Testing and adjusting, Part 2...390
Special functions of machine monitor...391
Testing and adjusting, Part 3...420
Procedure for turning on KOMTRAX terminal...421
Indication by KOMTRAX terminal lamps...424
Handling voltage circuit of engine controller...427
Preparation work for troubleshooting of electrical system...428
Procedure for testing diodes...432
Pm clinic service...433
40 Troubleshooting...0
Failure code table and fuse locations...440
Failure codes table...441
Before carrying out troubleshooting when failure code is displayed...445
General information on troubleshooting...450
Points to remember when troubleshooting...451
Sequence of events in troubleshooting...452
Checks before troubleshooting...453
Classification and troubleshooting steps...454
Information in troubleshooting table...455
Connection table for connector pin numbers...460
T- branch box and T- branch adapter table...496
Troubleshooting by failure code (Display of code), Part 1...500
Failure code [AA10NX] Air cleaner Clogging...503
Failure code [AB00KE] Charge Voltage Low...505
Failure code [B@BAZG] Eng Oil Press. Low...507
Failure code [B@BAZK] Eng Oil Level Low...509
Failure code [B@BCNS] Eng. Water Overheat...511
Failure code [B@BCZK] Eng Water Level Low...513
Failure code [B@HANS] Hydr Oil Overheat...515
Failure code [CA111] EMC Critical Internal Failure...517
Failure code [CA115] Eng Ne and Bkup Speed Sens Error...518
Failure code [CA122] Chg Air Press Sensor High Error...519
Failure code [CA123] Chg Air Press Sensor Low Error...521
Failure code [CA131] Throttle Sensor High Error...523
Failure code [CA132] Throttle Sensor Low Error...525
Failure code [CA144] Coolant Temp Sens High Error...527
Failure code [CA145] Coolant Temp Sens Low Error...529
Failure code [CA153] Chg Air Temp Sensor High Error...531
Failure code [CA154] Chg Air Temp Sensor Low Error...533
Failure code [CA155] Chg Air Temp High Speed Derate...535
Failure code [CA187] Sens Supply 2 Volt Low Error...537
Failure code [CA221] Ambient Press Sens High Error...539
Failure code [CA222] Ambient Press Sens Low Error...541
Failure code [CA227] Sens Supply 2 Volt High Error...543
Failure code [CA234] Eng Overspeed...544
Failure code [CA238] Ne Speed Sens Supply Volt Error...545
Failure code [CA271] IMV/PCV1 Short Error...546
Failure code [CA272] IMV/PCV1 Open Error...547
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error...549
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error...551
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error...553
Failure code [CA325] Inj #6 (L/B#6) Open/Short Error...555
Failure code [CA331] Inj #2 (L/B#2) Open/Short Error...557
Failure code [CA332] Inj #4 (L/B#4) Open/Short Error...559
Troubleshooting by failure code (Display of code), Part 2...562
Failure code [CA342] Calibration Code Incompatibility...564
Failure code [CA351] Injectors Drive Circuit Error...565
Failure code [CA352] Sens Supply 1 Volt Low Error...567
Failure code [CA386] Sens Supply 1 Volt High Error...569
Failure code [CA428] Water in Fuel Sensor High Error...571
Failure code [CA429] Water in Fuel Sensor Low Error...573
Failure code [CA435] Eng. Oil Press Sw Error...575
Failure code [CA441] Battery Voltage Low Error...577
Failure code [CA442] Battery Voltage High Error...579
Failure code [CA449] Rail Press Very High Error...581
Failure code [CA451] Rail Press Sensor High Error...585
Failure code [CA452] Rail Press Sensor Low Error...587
Failure code [CA553] Rail Press High Error...589
Failure code [CA559] Rail Press Low Error...590
Failure code [CA689] Eng Ne Speed Sensor Error...592
Failure code [CA731] Eng Bkup Speed Sens Phase Error...594
Failure code [CA757] All Persistent Data Lost Error...595
Failure code [CA778] Eng Bkup Speed Sensor Error...597
Failure code [CA1633] KOMNET Datalink Timeout Error...599
Failure code [CA2185] Throt Sens Sup Volt High Error...601
Failure code [CA2186] Throt Sens Sup Volt Low Error...602
Failure code [CA2249] Rail Press Very Low Error...603
Failure code [CA2265] Fuel Feed Pump Open Error...605
Failure code [CA2266] Fuel Feed Pump Short Error...607
Failure code [CA2311] IMV Solenoid Error...609
Failure code [CA2555] Grid Htr Relay Volt Low Error...611
Failure code [CA2556] Grid Htr Relay Volt High Error...613
Failure code [D110KB] Battery Relay Drive Short Circuit...615
Failure code [D196KA] Service Return Relay Disc...617
Failure code [D196KB] Service Return Relay S/C...619
Failure code [DA25KP] Press. Sensor Power Abnormality...621
Failure code [DA2RMC] Pump Comm. Abnormality...623
Failure code [DA2SKQ] Model Selection Abnormality...625
Troubleshooting by failure code (Display of code), Part 3...628
Failure code [DAFRMC] Monitor Comm. Abnormality...631
Failure code [DHPAMA] F Pump Press Sensor Abnormality...633
Failure code [DGH2KB] Hydr Oil Sensor Short Circuit...635
Failure code [DHPBMA] R Pump Press Sensor Abnormality...637
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality...639
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality...641
Failure code [DW43KA] Travel Speed Sol. Open Circuit...643
Failure code [DW43KB] Travel Speed Sol. Short Circuit...645
Failure code [DW45KA] Swing Brake Sol. Open Circuit...647
Failure code [DW45KB] Swing Brake Sol. Short Circuit...651
Failure code [DW91KA] Travel Junction Sol. Open Circuit...653
Failure code [DW91KB] Travel Junction Sol. Short Circuit...655
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit...657
Failure code [DWJ0KB] Merge-divider Sol. Short Circuit...659
Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit...661
Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit...663
Failure code [DXA0KA] PC-EPC Sol. Open Circuit...665
Failure code [DXA0KB] PC-EPC Sol. Short Circuit...667
Failure code [DXE0KA] LS-EPC Sol. Open Circuit...669
Failure code [DXE0KB] LS-EPC Sol. Short Circuit...671
Failure code [DXE4KA] Service Current EPC Open Circuit...673
Failure code [DXE4KB] Service Current EPC Short Circuit...674
Failure code [DY20KA] Wiper Working Abnormality...675
Failure code [DY20MA] Wiper Parking Abnormality...677
Failure code [DY2CKB] Washer Drive Short Circuit...679
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit...681
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...683
Troubleshooting of electrical system (E-mode)...686
Before carrying out troubleshooting of electrical system...689
Information contained in troubleshooting table...691
E-1 Engine does not start...692
E-2 Auto-decelerator does not operate...695
E-3 Automatic warming-up system does not operate...697
E-4 Preheater does not operate...699
E-5 All work equipment, swing, and travel mechanism do not move...701
E-6 Power maximizing function does not operate...703
E-7 Machine monitor does not display at all...705
E-8 Machine monitor does not display some items...707
E-9 Contents of display by machine monitor are different from applicable machine...707
E-10 Fuel level monitor was lighted in red while engine running...708
E-11 Engine coolant temperature gauge does not indicate normally...709
E-12 Hydraulic oil temperature gauge does not indicate normally...711
E-13 Fuel level gauge does not indicate normally...712
E-14 Swing lock monitor does not indicate normally...713
E-15 When monitor switch is operated, monitor displays nothing...715
E-16 Windshield wiper and window washer do not operate...717
E-17 Machine push-up function does not operate normally...721
E-18 Monitoring function fails to display ?boom raise? normally...723
E-19 Monitoring function fails to display ?boom lower? normally...725
E-20 Monitoring function fails to display ?arm IN? normally...727
E-21 Monitoring function fails to display ?arm OUT? normally...729
E-22 Monitoring function fails to display ?bucket CURL? normally...731
E-23 Monitoring function fails to display ?bucket DUMP? normally...733
E-24 Monitoring function fails to display ?swing? normally...735
E-25 Monitoring function fails to display ?travel? normally...737
E-26 Monitoring function fails to display ?travel differential pressure? normally...739
E-27 Monitoring function fails to display ?service? normally...741
E-28 KOMTRAX system does not operate normally...743
E-29 Air conditioner does not operate...745
E-30 Travel alarm does not sound or does not stop sounding...747
E-31 Horn does not sound...749
Troubleshooting of hydraulic and mechanical system (H-mode)...752
System chart for hydraulic and mechanical system...755
Information contained in troubleshooting table...757
H-1 All work equipment lack power, or travel and swing speeds are slow...759
H-2 Engine speed sharply drops or engine stalls...761
H-3 No work equipment, swing or travel move...762
H-4 Abnormal noise is heard from around hydraulic pump...762
H-5 Auto-decelerator does not work...763
H-6 Fine control mode does not function or responds slow...763
H-7 Boom moves slowly or lacks power...764
H-8 Arm moves slowly or lacks power...765
H-9 Bucket moves slowly or lacks power...766
H-10 Work equipment does not move in its single operation...766
H-11 Work equipment has a bit too fast hydraulic drift...767
H-12 Work equipment has big time lag...769
H-13 Other work equipment moves when relieving single circuit...769
H-14 Power max. switch does not operate...770
H-15 Machine push-up function does not operate...770
H-16 In compound operation, work equipment with larger load moves slowly...771
H-17 In swing + boom RAISE operation, boom moves slowly...771
H-18 In swing + travel operation, travel speed drops sharply...771
H-19 Machine swerves in travel...772
H-20 Machine travels slowly...773
H-21 Machine cannot be easily steered or lacks power...774
H-22 Travel speed does not shift, or it is too slow or fast...775
H-23 Track shoe does not turn (on one side only)...776
H-24 Machine does not swing...777
H-25 Swing acceleration is poor, or swing speed is slow...779
H-26 Excessive overrun when stopping swing...781
H-27 There is big shock when stopping swing...782
H-28 Large sound is made when upper structure stops swinging...782
H-29 Swing hydraulic drift is too big...783
Troubleshooting of engine (S-mode)...786
Method of using troubleshooting chart...788
S-1 Starting performance is poor...791
S-2 Engine does not start...792
S-3 Engine does not pick up smoothly...795
S-4 Engine stops during operations...796
S-5 Engine does not rotate smoothly...797
S-6 Engine lacks output (or lacks power)...798
S-7 Exhaust smoke is black (incomplete combustion)...799
S-8 Oil consumption is excessive (or exhaust smoke is blue)...800
S-9 Oil becomes contaminated quickly...801
S-10 Fuel consumption is excessive...802
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...803
S-12 Oil pressure drops...804
S-13 Oil level rises (Entry of coolant or fuel)...805
S-14 Coolant temperature becomes too high (overheating)...806
S-15 Abnormal noise is made...807
S-16 Vibration is excessive...808
50 Disassembly and assembly...0
General information on disassembly and assembly...810
How to read this manual...811
Coating materials list...813
Special tools list...816
Sketches of special tools...820
Engine and cooling system...824
Removal and installation of fuel supply pump assembly...825
Removal and installation of engine front seal...828
Removal and installation of engine rear seal...831
Removal and installation of cylinder head assembly...836
Removal and installation of radiator assembly...849
Removal and installation of hydraulic oil cooler assembly...851
Removal and installation of aftercooler assembly...853
Removal and installation of engine and hydraulic pump assembly...854
Power train...860
Removal and installation of final drive assembly...861
Disassembly and assembly of final drive assembly...862
Removal and installation of swing motor and swing machinery assembly...870
Disassembly and assembly of swing motor and swing machinery assembly...871
Removal and installation of swing circle assembly...878
Undercarriage and frame...880
Disassembly and assembly of carrier roller...881
Disassembly and assembly of track roller assembly...882
Disassembly and assembly of idler assembly...883
Disassembly and assembly of recoil spring...886
Removal and installation of sprocket...888
Expansion and installation of track shoe assembly...889
Removal and installation of revolving frame assembly...890
Removal and installation of counterweight assembly...892
Hydraulic system...894
Removal and installation of center swivel joint assembly...895
Disassembly and assembly of center swivel joint assembly...897
Removal and installation of hydraulic tank assembly...898
Removal and installation of control valve assembly...900
Disassembly and assembly of control valve assembly...903
Removal and installation of hydraulic pump assembly...905
Removal and installation of oil seal in hydraulic pump input shaft...907
Disassembly and assembly of work equipment PPC valve assembly...908
Disassembly and assembly of travel PPC valve assembly...910
Disassembly and assembly of hydraulic cylinder assembly...913
Work equipment...920
Removal and installation of work equipment assembly...921
Cab and its attachments...926
Removal and installation of operator's cab assembly...927
Removal and installation of operator?s cab glass (stuck glass)...930
Removal and installation of front window assembly...939
Electrical system...946
Removal and installation of assembly...947
Removal and installation of machine monitor...949
Removal and installation of pump controller...949
Removal and installation of KOMTRAX terminal...950
Removal and installation of engine controller...950
90 Diagrams and drawings...0
Hydraulic diagrams and drawings...952
Hydraulic circuit diagram...954
Electrical diagrams and drawings...957
Electrical circuit diagram...959
Connector list and stereogram...963
