Komatsu Hydraulic Excavator PC308USLC-3 Repair Service Manual & Operation Maintenance Manual & Parts Book
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC308USLC-3, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Excavators PC308USLC-3 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: 1,143 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM033101 - Hydraulic Excavator PC308USLC-3 Shop Manual.pdf
NJPT007900 - Hydraulic Excavator PC308USLC-3 Operation & Maintenance Manual & Parts Book.pdf
TEN00114-00 - Hydraulic Excavator GALEO PC308USLC-3 Operation & Maintenance Manual.pdf
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
REMOVAL OF WORK EQUIPMENT ASSEMBLY...826
INSTALLATION OF WORK EQUIPMENT ASSEMBLY...827
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...829
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...831
REMOVAL OF OPERATOR'S CAB ASSEMBLY...835
INSTALLATION OF OPERATOR'S CAB ASSEMBLY...836
REMOVAL OF FLOOR FRAME ASSEMBLY...837
INSTALLATION OF FLOOR FRAME ASSEMBLY...838
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY...839
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY...839
REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY...840
INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY...840
REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY...841
INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...842
REMOVAL, INSTALLATION OF COUNTERWEIGHT ASSEMBLY...843
REMOVAL OF MONITOR PANEL ASSEMBLY...844
INSTALLATION OF MONITOR PANEL ASSEMBLY...844
REMOVAL OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...845
INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...845
DISASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...846
ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...848
REMOVAL OF HYDRAULIC TANK ASSEMBLY...852
INSTALLATION OF HYDRAULIC TANK ASSEMBLY...853
90 OTHERS...855
HYDRAULIC CIRCUIT DIAGRAM...857
ELECTRICAL CIRCUIT DIAGRAM (1/4)...858
ELECTRICAL CIRCUIT DIAGRAM (2/4)...859
ELECTRICAL CIRCUIT DIAGRAM (3/4)...860
ELECTRICAL CIRCUIT DIAGRAM (4/4)...861
TEN00114-00 - Hydraulic Excavator GALEO PC308USLC-3 Operation & Maintenance Manual...862
COVER...862
FOREWORD...863
FOREWORD...864
SAFETY INFORMATION...867
INTRODUCTION...869
DIRECTIONS OF MACHINE...869
PRODUCT INFORMATION...870
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE...870
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...870
SERVICE METER LOCATION...871
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...871
CONTENTS...872
SAFETY...877
SAFETY INFORMATION...878
POSITION FOR ATTACHING SAFETY LABELS...880
POSITION FOR ATTACHING SAFETY LABELS...880
SAFETY LABELS...881
SAFETY INFORMATION...886
SAFETY RULES...886
IF ABNORMALITIES ARE FOUND...886
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...886
FIRE EXTINGUISHER AND FIRST AID KIT...886
SAFETY EQUIPMENT...887
KEEP MACHINE CLEAN...887
KEEP OPERATOR'S COMPARTMENT CLEAN...887
LEAVING OPERATOR'S SEAT WITH LOCK...887
HANDRAILS AND STEPS...888
CRUSHING OR CUTTING PREVENTION...889
MOUNTING AND DISMOUNTING...889
NO PERSONS ON ATTACHMENTS...889
BURN PREVENTION...889
FIRE PREVENTION AND EXPLOSION PREVENTION...890
ACTION IF FIRE OCCURS...891
WINDSHIELD WASHER FLUID...891
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...891
ATTACHMENT INSTALLATION...891
ATTACHMENT COMBINATIONS...892
CAB WIDOW GLASSES...892
UNAUTHORIZED MODIFICATIONS...892
SAFETY AT JOBSITE...892
WORKING ON LOOSE GROUND...893
DISTANCE TO HIGH VOLTAGE CABLES...893
ENSURE GOOD VISIBILITY...893
VENTILATION FOR ENCLOSED AREA...894
SIGNALMAN'S SIGNAL AND SIGNS...894
EMERGENCY EXIT FROM OPERATOR'S CAB...894
ASBESTOS DUST HAZARD PREVENTION...894
SAFETY MACHINE OPERATION...895
STARTING ENGINE...895
CHECKS BEFORE STARTING ENGINE...895
SAFETY RULES FOR STARTING ENGINE...896
STARTING ENGINE IN COLD WEATHER...896
OPERATION...897
CHECKS AFTER STARTING ENGINE...897
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...897
SAFETY RULES FOR TRAVELING...898
TRAVELING ON SLOPES...899
OPERATIONS ON SLOPES...900
PROHIBITED OPERATIONS...900
OPERATIONS ON SNOW...902
PARKING MACHINE...902
TRANSPORTATION...903
LOADING AND UNLOADING...903
SHIPPING THE MACHINE...904
BATTERY...905
BATTERY HAZARD PREVENTION...905
STARTING ENGINE WITH BOOSTER CABLES...906
TOWING...907
SAFETY RULES FOR TOWING...907
LIFTING OBJECTS WITH BUCKET...908
SAFETY RULES FOR LIFTING OBJECTS...908
SAFETY MAINTENANCE INFORMATION...909
WARNING TAG...909
KEEP WORK PLACE CLEAN AND TIDY...909
APPOINT LEADER WHEN WORKING WITH OTHERS...909
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...910
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...911
PROPER TOOLS...911
ACCUMULATOR...912
PERSONNEL...912
ATTACHMENTS...912
WORK UNDER THE MACHINE...912
NOISE...913
WHEN USING HAMMER...913
WELDING WORKS...913
REMOVING BATTERY TERMINALS...913
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...914
DO NOT DISASSEMBLE RECOIL SPRINGS...914
SAFETY RULES FOR HIGH-PRESSURE OIL...914
SAFETY HANDLING HIGH-PRESSURE HOSES...915
WASTE MATERIALS...915
AIR CONDITIONER MAINTENANCE...915
COMPRESSED AIR...915
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...916
OPERATION...917
GENERAL VIEW...918
GENERAL VIEW OF MACHINE...918
GENERAL VIEW CONTROLS AND GAUGES...919
EXPLANATION OF COMPONENTS...920
MACHINE MONITOR...920
BASIC CHECK ITEMS...921
SWITCHES...933
CONTROL LEVERS, PEDALS...939
FRONT WINDOW...942
SLIDING DOOR...948
ASHTRAY...948
CONTROLLER (COMPUTER)...948
REAR UNDERVIEW MIRROR...949
HAMMER FOR EMERGENCY ESCAPE...949
CAP, COVER WITH LOCK...950
HOT AND COOL BOX...951
HANDLING AIR CONDITIONER...952
RADIO...958
FUSE...963
FUSIBLELINK...964
TOOL COMPARTMENT...964
GREASE GUN HOLDER...964
HANDLING ACCUMULATOR...965
MACHINE OPERATIONS AND CONTROLS...966
BEFORE STARTING ENGINE...966
STARTING ENGINE...980
AFTER STARTING ENGINE...984
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)...987
STOPPING THE ENGINE...990
CHECK AFTER SHUT OFF ENGINE...990
MACHINE OPERATION...991
STEERING THE MACHINE...995
SWINGING...997
WORK EQUIPMENT CONTROLS AND OPERATIONS...998
OPERATING WORKING MODE...1000
PROHIBITED OPERATIONS...1001
GENERAL OPERATION INFORMATION...1003
TRAVELING ON SLOPES...1004
ESCAPE FROM MUD...1006
RECOMMENDED APPLICATIONS...1007
REPLACEMENT AND INVERSION OF BUCKET...1009
PARKING MACHINE...1012
CHECK AFTER FINISHING WORK...1013
LOCKING...1014
TRANSPORTATION...1015
TRANSPORTATION PROCEDURE...1015
LOADING AND UNLOADING WITH TRAILER...1016
LIFTING MACHINE...1025
COLD WEATHER OPERATION...1028
COLD WEATHER OPERATION INFORMATION...1028
AFTER DAILY WORK COMPLETION...1030
AFTER COLD WEATHER SEASON...1030
LONG TERM STORAGE...1031
BEFORE STORAGE...1031
DURING STORAGE...1031
AFTER STORAGE...1032
TROUBLESHOOTING...1033
AFTER RUNNING OUT OF FUEL...1033
PHENOMENA THAT ARE NOT FAILURES...1033
TOWING THE MACHINE...1034
LIGHTWEIGHT TOWING HOOK...1035
SEVERE JOB CONDITION...1035
DISCHARGED BATTERY...1036
OTHER TROUBLE...1040
MAINTENANCE...1047
MAINTENANCE INFORMATION...1048
LUBRICANTS, COOLANT AND FILTERS...1051
OUTLINE OF OIL, FUEL, COOLANT...1051
ELECTRIC SYSTEM MAINTENANCE...1053
HANDLING HYDRAULIC SYSTEM...1053
WEAR PARTS LIST...1055
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...1056
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...1056
TIGHTENING TORQUE SPECIFICATIONS...1060
TIGHTENING TORQUE LIST...1060
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1061
SAFETY CRITICAL PARTS...1061
MAINTENANCE SCHEDULE...1062
MAINTENANCE SCHEDULE CHART...1062
MAINTENANCE PROCEDURE...1064
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...1064
REPLACE FUEL FILTER CARTRIDGE...1090
CHECK ENGINE VALVE CLEARANCE, ADJUST...1104
WHEN REQUIRED...1065
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...1065
CLEAN INSIDE OF COOLING SYSTEM...1068
CHECK AND TIGHTEN TRACK SHOE BOLTS...1071
CHECK AND ADJUST TRACK TENSION...1072
CHECK ELECTRICAL INTAKE AIR HEATER...1074
ADJUST BUCKET CLEARANCE...1075
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...1076
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)...1077
WASHING WASHABLE FLOOR...1078
BLEEDING AIR FROM HYDRAULIC SYSTEM...1079
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...1081
CHECK BEFORE STARTING...1082
EVERY 100 HOURS MAINTENANCE...1083
LUBRICATING...1083
DRAIN WATER AND SEDIMENT FROM FUEL TANK...1084
EVERY 250 HOURS MAINTENANCE...1085
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...1085
CHECK LEVEL OF BATTERY ELECTROLYTE...1086
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...1088
LUBRICATE SWING CIRCLE (2 PLACES)...1088
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL...1089
EVERY 500 HOURS MAINTENANCE...1090
REPLACE FUEL FILTER CARTRIDGE...1090
CHECK SWING PINION GREASE LEVEL, ADD GREASE...1091
LUBRICATING...1092
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...1094
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM...1096
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...1097
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...1098
EVERY 1000 HOURS MAINTENANCE...1099
REPLACE HYDRAULIC FILTER ELEMENT...1099
CHANGE OIL IN SWING MACHINERY CASE...1101
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...1102
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...1102
CHECK PLAY OF TURBOCHARGER ROTOR...1102
CHECK FAN BELT TENSION AND REPLACE FAN BELT...1102
EVERY 2000 HOURS MAINTENANCE...1103
CHANGE OIL IN FINAL DRIVE CASE...1103
CLEAN HYDRAULIC TANK STRAINER...1104
CLEAN, CHECK TURBOCHARGER...1104
CHECK ALTERNATOR, STARTING MOTOR...1104
CHECK ENGINE VALVE CLEARANCE, ADJUST...1104
CHECK VIBRATION DAMPER...1105
EVERY 4000 HOURS MAINTENENCE...1106
CHECK WATER PUMP...1106
EVERY 5000 HOURS MAINTENANCE...1107
CHANGE OIL IN HYDRAULIC TANK...1107
SPECIFICATIONS...1109
SPECIFICATIONS...1110
ATTACHMENTS AND OPTIONS...1113
GENERAL PRECAUTIONS...1114
PRECAUTIONS RELATED TO SAFETY...1114
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...1116
HANDLING BUCKET WITH HOOK...1117
CHECKING FOR DAMAGE TO BUCKET WITH HOOK...1117
PROHIBITED OPERATIONS...1117
MACHINES READY FOR ATTACHMENTS...1118
EXPLANATION OF COMPONENTS...1118
HYDRAULIC CIRCUIT...1122
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...1127
OPERATION...1129
LONG-TERM STORAGE...1130
SPECIFICATIONS...1130
ATTACHMENT GUIDE...1131
SELECTION OF TRACK SHOES...1132
RECOMMENDED ATTACHMENT OPERATIONS...1133
HYDRAULIC BREAKER...1133
INDEX...1139
