Komatsu Hydraulic Excavators PC300LC-7L, PC300HD-7L, PC300LL-7L Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC300LC-7L, PC300HD-7L, PC300LL-7L, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC300LC-7L, PC300HD-7L, PC300LL-7L 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: 3,211 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
SAFETY...5
SAFETY NOTICE...5
FOREWARD...7
GENERAL...7
HOW TO READ THE SHOP MANUAL...8
HOISTING INSTRUCTIONS...9
COATING MATERIALS...10
STANDARD TIGHTENING TORQUE...12
ELECTRIC WIRE CODE...17
CONVERSION TABLES...18
UNITS...23
01 GENERAL...25
DIMENSION DRAWINGS...26
DIMENSIONS...26
WORKING RANGES...28
SPECIFICATIONS...30
WEIGHT TABLE...33
POWERED CAB RISER TILT UNIT TARGETS...35
FUEL COOLANT AND LUBRICANTS...36
PC300LL-7L...36
10 STRUCTURE AND FUNCTION...37
ENGINE RELATED PARTS...39
RADIATOR . OIL COOLER . AFTERCOOLER...40
FINAL DRIVE SYSTEM...42
PC300LL-7L...42
SWING MACHINERY...45
SWING CIRCLE...48
TRACK FRAME . RECOIL SPRING...50
PC300LL-7L...50
IDLER...51
TRACK ROLLER...53
TRACK SHOE...54
TRIPLE GROUSER SHOE...56
HYDRAULIC EQUIPMENT...57
HYDRAULIC TANK...59
HYDRAULIC PUMP...60
HPV125 + 125...60
LS VALVE...65
PC VALVE...65
LS(PC)-EPC VALVE...77
VARIABLE VOLUME VALVE...80
CONTROL VALVE...82
MAIN RELIEF VALVE...93
VARIABLE PRESSURE COMPENSATION VALVE...94
CLSS...95
SELF PRESSURE REDUCING VALVE...98
SWING MOTOR...101
SUCTION-SAFETY VALVE...104
SWING BRAKE...105
CENTER SWIVEL JOINT...106
PC300LL-7L...107
MOTOR OPERATION...109
PARKING BRAKE OPERATION...111
BRAKE VALVE OPERATION...112
TRAVEL JUNCTION VALVE...116
TRAVEL PPC SHUTTLE VALVE...118
VALVE CONTROL...122
WORK EQUIPMENT . SWING PPC VALVE...123
TRAVEL PPC VALVE...127
ATTACHMENT SOLENOID VALVE...136
PPC ACCUMULATOR...138
BOOM HYDRAULIC DRIFT PREVENTION VALVE...139
QUICK RETURN VALVE...145
LIFT CHECK VALVE...147
HYDRAULIC CYLINDER...148
BOOM CYLINDER...148
ARM CYLINDER...148
BUCKET CYLINDER...149
WORK EQUIPMENT...150
DIMENSION OF ARM...152
DIMENSION OF BUCKET...154
AIR CONDITIONER...156
PIPING...156
ENGINE CONTROL...157
FUEL CONTROL DIAL...159
GOVERNOR MOTOR...160
ENGINE THROTTLE AND PUMP CONTROLLER...161
INPUT AND OUTPUT SIGNALS...162
ELECTRONIC CONTROL SYSTEM...163
TOTAL SYSTEM DIAGRAM...164
MULTI MONITOR SYSTEM...187
MONITOR PANEL...188
MONITOR CONTROL, DISPLAY PORTION /MONITOR PORTION...190
MAINTENANCE FUNCTION...201
SENSORS...206
ENGINE OIL LEVEL SENSOR...206
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)...206
COOLANT TEMPERATURE SENSOR...207
HYDRAULIC OIL TEMPERATURE SENSOR...207
FUEL LEVEL SENSOR...208
AIR CLEANER CLOGGING SENSOR...208
CAB RISER AND RELATED PARTS...209
POWER CONTROL...210
STRESS TARGETS FOR CAB RISER KIT...211
CAB RISER HYDRAULIC SYSTEM...212
20 TESTING, ADJUSTING AND TROUBLESHOOTING...213
STANDARD VALUE TABLES...215
ENGINE RELATED...215
CHASSIS RELATED...216
SERVICE TOOLS...224
ENGINE...224
AIR BOOST PRESSURE...224
AIR COMPRESSOR BELT TENSION...224
BLOW-BY PRESSURE...224
COMPRESSION PRESSURE...224
ENGINE OIL PRESSURE...224
ENGINE RPM...224
ENGINE SPEED SENSOR...225
EXHAUST GAS COLOR...225
FUEL INJECTION TIMING...225
VALVE CLEARANCE...225
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE...226
SWING CIRCLE BEARINGS...226
TRACK SHOE TENSION...227
SPROCKET...228
OIL PRESSURE...228
WORK EQUIPMENT, SWING AND TRAVEL...228
CONTROL CIRCUIT...233
PUMP PC CONTROL CIRCUIT...234
PUMP LS CONTROL CIRCUIT...237
ATTACHMENT SOLENOID VALVE OUTPUT...241
ATTACHMENT PPC VALVE OUTPUT...244
WORK EQUIPMENT AND SWING PPC VALVE...245
WORK EQUIPMENT, HYDRAULIC DRIFT LOCATIONS...245
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT...246
BOOM AND BUCKET CYLINDERS...246
BOOM LOCK VALVE...246
ARM CYLINDER...247
PPC VALVE...247
OIL LEAKAGE AMOUNT...249
BOOM CYLINDER...249
ARM CYLINDER...249
BUCKET CYLINDER...250
SWING MOTOR...250
TRAVEL MOTOR...250
AIR BLEEDING OF VARIOUS PARTS...251
DIODE INSPECTION PROCEDURES...253
MULTI-MONITOR PANEL...254
MONITOR PANEL FUNCTIONS...255
OPERATOR?S MENU AND DISPLAY (OUTLINE)...256
TABLE FOR SERVICE AND FAILURE CODE NOS...261
SERVICE MENU...263
WAY OF SWITCHING TO SERVICE MENU...263
TABLE FOR MONITORING ITEMS...266
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARTIONS...278
PM TUNE SERVICE...279
TROUBLESHOOTING (GENERAL)...283
POINTS TO REMEMBER WHEN TROUBLESHOOTING...284
SEQUENCE OF EVENTS IN TROUBLESHOOTING...286
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...287
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT...287
HANDLING CONTROL BOX...292
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS...293
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...294
CHECKS BEFORE TROUBLESHOOTING...296
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS...297
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO...298
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...301
T-ADAPTER TABLE...325
TROUBLESHOOTING ELECTRICAL SYSTEM (E MODE)...329
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...331
ABNORMALITY RETURNS TO NORMAL BY ITSELF...331
USER CODE MEMORY RETENTION FUNCTION...331
INFORMATION CONTAINED IN TESTING PROCEDURES...332
(E101)...334
ABNORMAL DATA IN ERROR HISTORY...334
(E112)...336
SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION...336
(E113)...338
SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION...338
(E114)...340
SHORT OR OPEN IN WINDOW WASHER SYSTEM...340
(E115)...342
ABNORMAL WINDSHIELD WIPER MOTION...342
(E116)...344
ABNORMALITY IN PARKING WIPER ARM...344
(E201)...346
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID...346
(E203)...348
SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM...348
(E204)...350
SHORT IN MERGE/DIVIDE SOLENOID...350
(E205)...352
SHORT IN 2 STAGE RELIEF SOLENOID...352
(E206)...354
SHORT IN TRAVEL SPEED SHIFT SOLENOID...354
(E211)...356
OPEN IN TRAVEL INTERLOCKING SOLENOID...356
(E213)...358
OPEN IN SWING PARKING BRAKE SOLENOID...358
(E214)...360
OPEN OF MERGE/DIVIDE SOLENOID...360
(E215)...362
OPEN IN 2 STAGE RELIEF SOLENOID...362
(E216)...364
OPEN IN TRAVEL SPEED SOLENOID...364
(E217)...366
ABNORMAL INPUT FOR MODEL CODE...366
(E218)...368
OPEN IN S-NET SIGNAL...368
(E222)...370
SHORT IN LS-EPC SOLENOID...370
(E223)...372
OPEN IN LS-EPC SOLENOID SYSTEM...372
(E224)...374
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL...374
(E225)...376
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL...376
(E226)...378
ABNORMAL PRESSURE SENSOR POWER SUPPLY...378
(E227)...380
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER...380
(E228)...382
SHORT IN ATTACHMENT RETURN SWITCHING RELAY...382
(NO CODE)...384
SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM...384
(NO CODE)...387
OPEN IN CAB TILT SYSTEM...387
(E232)...389
SHORT IN PC-EPC SOLENOID...389
(E233)...391
OPEN IN PC-EPC SOLENOID SYSTEM...391
(E238)...393
OPEN IN ATTACHMENT RETURN SWITCH RELAY...393
(E245)...395
SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM...395
(E246)...397
OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM...397
(E256)...399
INCORRECT NON-VOLATILE MEMORY DATA...399
(E304)...401
SHORT IN ENGINE STOP SOLENOID SYSTEM...401
(E314)...403
OPEN IN ENGINE STOP SOLENOID SYSTEM...403
(E306)...405
ABNORMAL GOVERNOR POTENTIOMETER SIGNALS...405
(E308)...407
ABNORMAL FUEL DIAL SIGNALS...407
(E315)...409
SHORT IN BATTERY RELAY SYSTEM...409
(E316)...411
STEP OUT IN GOVERNOR MOTOR...411
(E317)...413
OPEN IN GOVERNOR MOTOR PHASE ?A? AND ?B?...413
(E318)...415
SHORT IN GOVERNOR MOTOR PHASE ?A? AND ?B?...415
(E501)...417
MODEL SELECTION FUNCTION NOT PROVIDED...417
(E502)...418
MODEL SELECTING SIGNAL FAULT...418
(AA10NX)...419
AIR CLEANER CLOG INDICATOR FAILURE...419
(AB00KE)...420
LOW CHARGING VOLTAGE INDICATED...420
(B@BAZG)...422
ABNORMAL ENGINE OIL PRESSURE...422
(B@BAZK)...423
ABNORMAL ENGINE OIL LEVEL...423
(B@BCNS)...424
ENGINE COOLANT INDICATING OVERHEAT CONDITION...424
(B@BCZK)...425
ABNORMAL COOLANT LEVEL INDICATION...425
(B@HANS)...426
HYDRAULIC OIL OVERHEAT INDICATION...426
TROUBLESHOOTING MONITOR ELECTRICAL SYSTEM (E MODE)...427
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...428
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF...428
USER CODE MEMORY RETENTION FUNCTION...428
INFORMATION CONTAINED IN TESTING PROCEDURES...429
(E-1)...431
ENGINE WILL NOT CRANK...431
(E-2)...433
ENGINE STOPS WHILE IN OPERATION...433
(E-3)...435
ENGINE SPEED IRREGULAR, OR HUNTING...435
(E-4)...437
ENGINE DOES NOT SHUT DOWN...437
(E-5)...439
AUTO DECELERATOR DOES NOT WORK...439
(E-6)...440
AUTO ENGINE WARM UP DEVICE DOES NOT WORK...440
(E-7)...441
