Komatsu Hydraulic Excavator PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 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: 1,182 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN06257-02 - Hydraulic Excavator PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 Shop Manual.pdf
MAIN SECTIONS
COVER...1
00 Index and foreword...0
100 Index...3
Composition of shop manual...4
Table of contents...6
200 Foreword and general information...17
Foreword, safety and general information...18
How to read the shop manual...25
Explanation of terms for maintenance standard...27
Handling equipment of fuel system devices...29
Handling of intake system parts...30
Handling of hydraulic equipment...31
Method of disconnecting and connectingof push-pull type coupler...33
Handling of electrical equipment...36
How to read electric wire code...45
Precautions when performing operation...48
Practical use of KOMTRAX...51
Standard tightening torque table...52
List of abbreviation...56
Conversion table...61
01 Specification...67
100 Specification and technical data...67
Specification dimension drawings...68
Specifications...70
Weight table...76
Table of fuel, coolant and lubricants...78
10 Structure, function andmaintenance standard...0
100 Engine and cooling system...81
Engine related parts...82
Radiator, oil cooler and aftercooler...83
200 Power train...85
Power train...86
Swing circle...87
Swing machinery...88
Final drive...90
Sprocket...92
300 Undercarriage and frame...95
Track frame and recoil spring...96
Idler...98
Carrier roller...100
Track roller...101
Track shoe...103
401 Hydraulic system, Part 1...107
Hydraulic equipment layout drawing...108
Hydraulic tank and filter...110
Hydraulic pump...112
402 Hydraulic system, Part 2...137
Control valve...138
CLSS...150
Functions and operation by valve...154
Attachment circuit selector valve...193
Hydraulic drift prevention valve...196
403 Hydraulic system, Part 3...203
Valve control...204
PPC valve...206
Solenoid valve...226
PPC accumulator...228
Center swivel joint...229
Travel motor...231
Swing motor...243
Work equipment cylinder...251
500 Work equipment...255
Work equipment...256
Dimensions of components...258
600 Electrical system...263
Engine control system...264
Electronic control system...273
Machine monitor system...298
Sensor...318
KOMTRAX system...321
20 Standard value table...329
100 Standard service value table...329
Standard value table for engine related parts...330
Standard value table for chassis related parts...331
30 Testing and adjusting...0
101 Testing and adjusting, Part 1...343
Tools for testing, adjusting and troubleshooting...345
Sketches of special tools...349
Testing engine speed...350
Testing air boost pressure...351
Testing exhaust gas color...352
Adjusting valve clearance...354
Testing compression pressure...356
Testing blowby pressure...360
Testing engine oil pressure...361
Testing fuel pressure...362
Handling during cylinder cutout operation...367
Handling during no-injection cranking operation...367
Testing fuel return rate and leakage...368
Bleeding air from fuel circuit...370
Checking fuel circuit for leakage...371
Testing and adjusting air compressor belt tension...372
Replacing fan belt...373
Replacing alternator belt...374
Testing clearance in swing circle bearings...375
Testing and adjusting track tension...376
Testing and adjusting oil pressure in work equipment, swing and travel circuit...377
Testing control circuit oil pressure...381
Testing and adjusting pump PC control circuit oil pressure...382
Testing and adjusting pump LS control circuit oil pressure...385
Testing solenoid valve output pressure...390
Testing PPC valve output pressure...394
Adjusting play of work equipment and swing PPC valves...395
Inspecting locations of hydraulic drift of work equipment...396
Releasing remaining pressure in hydraulic circuit...398
Testing oil leakage amount...399
Bleeding air from various parts...401
102 Testing and adjusting, Part 2...405
Special functions of machine monitor...406
103 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
100 Failure code table and fuse locations...473
Failure codes table...474
Fuse locations...482
200 General Information on troubleshooting...485
Symptom and troubleshooting numbers...486
Sequence of events in troubleshooting...488
Checks before troubleshooting...490
Classification and procedures for troubleshooting...492
Symptom and troubleshooting numbers...494
Information in troubleshooting table...496
Connector list and layout...498
Connection table for connector pin numbers...508
T- branch box and T- branch adapter table...544
Troubleshooting method for open circuit in wiring harness of pressure sensor system...547
301 Troubleshooting by failure code, Part 1...551
Failure code [879AKA] A/C Inner Sensor Open Circuit...553
Failure code [879AKB] A/C Inner Sensor Short Circuit...553
Failure code [879BKA] A/C Outer Sensor Open Circuit...553
Failure code [879BKB] A/C Outer Sensor Short Circuit...553
Failure code [879CKA] Ventilating Sensor Open Circuit...553
Failure code [879CKB] Ventilating Sensor Short Circuit...554
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit...554
Failure code [879EMC] Ventilation Damper Abnormality...554
Failure code [879FMC] Air Mix Damper Abnormality...554
Failure code [879GKX] Refrigerant Abnormality...554
Failure code [989L00] Engine Controller Lock Caution1...555
Failure code [989M00] Engine Controller Lock Caution2...556
Failure code [989N00] Engine Controller Lock Caution3...557
Failure code [AA10NX] Air Cleaner Clogging...558
Failure code [AB00KE] Charge Voltage Low...560
Failure code [B@BAZG] Eng Oil Press Low...562
Failure code [B@BAZK] Engine Oil Level Low...563
Failure code [B@BCNS] Eng Water Overheat...564
Failure code [B@BCZK] Radiator Coolant Level Low...566
Failure code [B@HANS] Hyd Oil Overheat...568
Failure code [CA111] ECM Critical Internal Failure...569
Failure code [CA115] Eng Ne and Bkup Speed Sens Error...569
Failure code [CA122] Chg Air Press Sensor High Error...570
Failure code [CA123] Chg Air Press Sensor Low Error...572
Failure code [CA131] Throttle Sensor High Error...574
Failure code [CA132] Throttle Sensor Low Error...576
Failure code [CA144] Coolant Temp Sens High Error...578
Failure code [CA145] Coolant Temp Sens Low Error...580
Failure code [CA153] Chg Air Temp Sensor High Error...582
Failure code [CA154] Chg Air Temp Sensor Low Error...584
Failure code [CA155] Chg Air Temp High Speed Derate...586
Failure code [CA187] Sens Supply 2 Volt Low Error...588
Failure code [CA221] Ambient Press Sens High Error...590
Failure code [CA222] Ambient Press Sens Low Error...592
Failure code [CA227] Sens 2 Supply Volt High Error...594
Failure code [CA234] Eng Overspeed...594
Failure code [CA238] Ne Speed Sens Supply Volt Error...595
Failure code [CA271] IMV/PCV1 Short Error...596
Failure code [CA272] IMV/PCV1 Open Error...598
Failure code [CA281] Abnormal supply pump pressure balance...600
302 Troubleshooting by failure code, Part 2...603
Failure code [CA322] Inj #1(L#1) Open/Short Error...606
Failure code [CA323] Inj #5(L#5) Open/Short Error...608
Failure code [CA324] Inj #3(L#3) Open/Short Error...610
Failure code [CA325] Inj #6(L#6) Open/Short Error...612
Failure code [CA331] Inj #2(L#2) Open/Short Error...614
Failure code [CA332] Inj #4(L#4) Open/Short Error...616
Failure code [CA342] Calibration Code Incompatibility...618
Failure code [CA351] Injectors Drive Circuit Error ...619
Failure code [CA352] Sens Supply 1 Volt Low Error ...620
Failure code [CA386] Sens Supply 1 Volt High Error...622
Failure code [CA428] Water in Fuel Sensor High Error ...624
Failure code [CA429] Water in Fuel Sensor Low Error ...626
Failure code [CA435] Eng Oil Press Sw Error ...628
Failure code [CA441] Battery Voltage Low Error ...630
Failure code [CA442] Battery Voltage High Error ...632
Failure code [CA449] Rail Press Very High Error ...633
Failure code [CA451] Rail Press Sensor High Error ...634
Failure code [CA452] Rail Press Sensor Low Error...636
Failure code [CA488] Chg Air Temp High Torque Derate ...638
Failure code [CA553] Rail Press High Error ...639
Failure code [CA559] Rail Press Low Error ...640
Failure code [CA689] Eng Ne Speed Sensor Error...642
Failure code [CA731] Eng Bkup Speed Sens Phase Error ...646
Failure code [CA757] All Continuous Data Lost Error...647
Failure code [CA778] Eng Bkup Speed Sensor Error ...648
Failure code [CA2185] Throt Sens Sup Volt High Error ...651
Failure code [CA2186] Throt Sens Sup Volt Low Error...652
Failure code [CA2249] Rail Press Very Low Error ...653
Failure code [CA2265] Fuel Feed Pump Open Error...654
Failure code [CA2266] Fuel Feed Pump Short Error...656
Failure code [CA2311] lMV Solenoid Error ...657
Failure code [CA2555] Grid Htr Relay Open Circuit Error...658
Failure code [CA2556] Grid Htr Relay Short Circuit Error...660
303 Troubleshooting by failure code, Part 3...663
Failure code [D110KB] Battery Relay Drive Short Circuit...666
Failure code [D19JKZ] Personal Code Relay Abnormality...668
Failure code [D811MC] KOMTRAX Error...670
Failure code [D862KA] GPS Antenna Open Circuit...671
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)...672
Failure code [DA22KK] Pump Solenoid Power Low Error...674
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...676
Failure code [DA26KP] 5V Sensor 2 Power Abnormality...678
Failure code [DA29KQ] Model Selection Abnormality...680
Failure code [DA2QKR] CAN2 Discon (Pump Con)...682
Failure code [DAF0MB] Monitor ROM Abnormality...685
Failure code [DAF0MC] Monitor Error...686
Failure code [DAF8KB] Camera Power Supply Short Circuit...688
Failure code [DAF9KQ] Model Selection Abnormality...690
Failure code [DAFGMC] GPS Module Error...691
Failure code [DAFQKR] CAN2 Discon...692
Failure code [DAZ9KQ] A/C Model Selection Abnormality...693
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)...694
Failure code [DB2QKR] CAN2 Discon (Engine Con)...696
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit...700
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit...702
Failure code [DHPAMA] F Pump Press Sensor Abnormality...704
Failure code [DHPBMA] R Pump Press Sensor Abnormality...706
304 Troubleshooting by failure code, Part 4...709
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality...712
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality...714
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality...716
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality...718
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality...720
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality...722
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality...724
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality...726
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality...728
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality...730
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality...732
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality...734
Failure code [DHX1MA] Overload Sensor Abnormality...736
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality...738
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality...740
Failure code [DV20KB] Travel Alarm Short Circuit...742
Failure code [DW43KA] Travel Speed Sol Open Circuit...744
Failure code [DW43KB] Travel Speed Sol Short Circuit...746
Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit...748
Failure code [DW45KB] Swing Brake Sol Short Circuit...750
Failure code [DW91KA] Travel Neutral Sol Open Circuit...752
Failure code [DW91KB] Travel Neutral Sol Short Circuit...754
305 Troubleshooting by failure code, Part 5...757
Failure code [DWA2KA] Attachment Sol Open Circuit...758
Failure code [DWA2KB] Attachment Sol Short Circuit...760
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit...762
Failure code [DWJ0KB] Merge-divider Sol. Short Circuit...764
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit...766
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit...768
Failure code [DWK2KA] Variable Back Press Sol Open Circuit...770
Failure code [DWK2KB] Variable Back Press Sol Short Circuit...772
Failure code [DXA8KA] PC-EPC Sol Open Circuit...774
Failure code [DXA8KB] PC-EPC Sol Short Circuit...776
Failure code [DXE0KA] LS-EPC Sol Open Circuit...778
Failure code [DXE0KB] LS-EPC Sol Short Circuit...780
Failure code [DXE4KA] Attachment Flow EPC Open Circuit...782
Failure code [DXE4KB] Attachment Flow EPC Short Circuit...784
Failure code [DY20KA] Wiper Working Abnormality...786
Failure code [DY20MA] Wiper Parking Abnormality...788
Failure code [DY2CKB] Washer Drive Short Circuit...790
Failure code [DY2DKB] Wiper Drive (Fwd) Short...792
Failure code [DY2EKB] Wiper Drive (Rev) Short...794
400 Troubleshooting of electrical system (E-mode)...797
Fuse locations...800
Information contained in troubleshooting table...802
E-1 Engine does not start (Engine does not crank)...804
E-2 Preheater does not operate...809
E-3 When starting switch is turned to ON position, machine monitor displays nothing...813
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up...816
E-5 Precaution monitor lights up while engine is running...817
E-6 Emergency stop monitor lights up while engine is running...819
E-7 Fuel level gauge does not indicate properly...820
E-8 Engine coolant temperature gauge does not indicate properly...822
E-9 Hydraulic oil temperature gauge does not indicate properly...823
E-10 Displays on machine monitor are different from those for actual machine...826
E-11 Some areas of machine monitor screen are not displayed...827
E-12 Function switch does not operate...827
E-13 Automatic warm-up system does not operate (in cold season)...828
E-14 Auto-decelerator does not operate properly...829
E-15 Working mode does not change...830
E-16 Travel speed does not change...831
E-17 Alarm buzzer cannot be canceled...832
E-18 When starting switch is turned OFF, service meter is not displayed...832
E-19 Service mode cannot be selected...832
E-20 Any of work equipment, swing and travel do not operate or cannot be locked...833
E-21 Swing holding brake does not operate properly...835
E-22 One-touch power maximizing function does not operate properly...838
E-23 Travel alarm does not sound or does not stop sounding...841
E-24 Horn does not sound or does not stop...842
E-25 Windshield wiper and window washer do not operate...844
E-26 Machine push-up function cannot be canceled...846
E-27 Machine push-up function does not operate...848
E-28 BOOM DOWN indicator is not displayed properly with monitoring function...849
E-29 ARM DUMP indicator is not displayed properly with monitoring function...849
E-30 ARM IN indicator is not displayed properly with monitoring function...849
E-31 BOOM RAISE indicator is not displayed properly with monitoring function...850
E-32 BUCKET CURL indicator is not displayed properly with monitoring function...850
E-33 BUCKET DUMP indicator is not displayed properly with monitoring function...850
E-34 SWING indicator is not displayed properly with monitoring function...851
E-35 TRAVEL indicator is not displayed properly with monitoring function...851
E-36 ATTACHMENT indicator is not displayed properly with monitoring function...852
E-37 Attachment hydraulic circuit cannot be changed...854
E-38 KOMTRAX system does not operate properly...855
500 Troubleshooting of hydraulic and mechanical system (H-mode)...857
System chart for hydraulic and mechanical system...860
Information contained in troubleshooting table...862
H-1 All work equipment lack power, or travel and swing speeds are slow...864
H-2 Engine speed sharply drops or engine stalls...866
H-3 No work equipment, swing or travel move...867
H-4 Abnormal noise is heard from around hydraulic pump...867
H-5 Auto-decelerator does not work...868
H-6 Fine control mode does not function or responds slow...868
H-7 Boom moves slowly or lacks power...869
H-8 Arm moves slowly or lacks power...870
H-9 Bucket moves slowly or lacks power...871
H-10 Work equipment does not move in its single operation...871
H-11 Work equipment has a bit too fast hydraulic drift...872
H-12 Work equipment has big time lag...874
H-13 Other work equipment moves when relieving single circuit...874
H-14 Power max. switch does not operate...875
H-15 In compound operation, work equipment with larger load moves slowly...875
H-16 In swing + boom RAISE operation, boom moves slowly...876
H-17 In swing + travel operation, travel speed drops sharply...876
H-18 Machine swerves in travel...877
H-19 Machine travels slowly...878
H-20 Machine cannot be easily steered or lacks power...879
H-21 Travel speed does not shift, or it is too slow or fast...880
H-22 Track shoe does not turn (on one side only)...881
H-23 Machine does not swing...882
H-24 Swing acceleration is poor, or swing speed is slow...884
H-25 Excessive overrun when stopping swing...886
H-26 There is big shock when stopping swing...887
H-27 Large sound is made when upper structure stops swinging...887
H-28 Swing hydraulic drift is too big...888
600 Troubleshooting of engine (S-mode)...891
Method of using troubleshooting charts...893
S-1 Starting performance is poor...896
S-2 Engine does not start...897
S-3 Engine does not pick up smoothly...900
S-4 Engine stops during operations...901
S-5 Engine does not rotate smoothly...902
S-6 Engine lacks output (or lacks power)...903
S-7 Exhaust smoke is black (incomplete combustion)...904
S-8 Oil consumption is excessive (or exhaust smoke is blue)...905
S-9 Oil becomes contaminated quickly...906
S-10 Fuel consumption is excessive...907
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)...908
S-12 Oil pressure drops...909
S-13 Oil level rises (water, fuel in oil)...910
S-14 Coolant temperature becomes too high (overheating)...911
S-15 Abnormal noise is made...912
S-16 Vibration is excessive...913
50 Disassembly and assembly...0
100 Related information on disassembly and assembly...915
How to read this manua...916
Coating materials list...918
Special tools list...922
Sketches of special tools...926
200 Engine and cooling system...931
Removal and installation of supply pump assembly...932
Removal and installation of engine front oil seal...936
Removal and installation of engine rear oil seal...939
Removal and installation of cylinder head assembly...944
Removal and installation of radiator assembly...958
Removal and installation of hydraulic oil cooler assembly...960
Removal and installation of aftercooler assembly...962
Removal and installation of engine and hydraulic pump assembly...964
300 Power train system...971
Removal and installation of travel motor and final drive assembly...972
Disassembly and assembly of final drive assembly...973
Removal and installation of swing motor and swing machinery assembly...983
Disassembly and assembly of swing motor and swing machinery assembly...984
Removal and installation of swing circle assembl...992
400 Undercarriage and frame...995
Disassembly and assembly of carrier roller assembly...996
Disassembly and assembly of track roller assembly...999
Removal and installation of idler and idler cushion assembly...1001
Disassembly and assembly of idler assembly...1002
Disassembly and assembly of recoil spring assembly...1005
Removal and installation of sprocket...1007
Separation and connection of track assembly...1008
Removal and installation of revolving frame assembly...1012
Removal and installation of counterweight assembly...1014
500 Hydraulic system...1019
Removal and installation of center swivel joint assembly...1020
Disassembly and assembly of center swivel joint assembly...1022
Removal and installation of hydraulic tank assembly...1023
Removal and installation of control valve assembly...1025
Disassembly and assembly of control valve assembly...1028
Removal and installation of hydraulic pump assembly...1033
Removal and installation of hydraulic pump input shaft oil seal...1036
Disassembly and assembly of work equipment PPC valve assembly...1037
Disassembly and assembly of travel PPC valve assembly...1039
Disassembly and assembly of work equipment cylinder assembly...1041
600 Work equipment...1049
Removal and installation of work equipment assembly...1050
700 Cab and its attachments...1055
Removal and installation of operator's cab assembly...1056
Removal and installation of operator's cab glass (adhered window glass)...1059
Removal and installation of front window assembly...1068
Removal and installation of floor frame assembly...1074
800 Electrical system...1079
Removal and installation of air conditioner unit assembly...1080
Removal and installation of KOMTRAX terminal assembly...1085
Removal and installation of machine monitor assembly...1087
Removal and installation of pump controller assembly...1089
Removal and installation of engine controller assembly...1091
80 Appendix...0
100 Air conditioner...1093
Precautions for refrigerant...1095
Air conditioner component...1096
Configuration and function of refrigeration cycle ...1098
Outline of refrigeration cycle...1099
Air conditioner unit...1101
Air conditioner controller...1107
Compressor...1108
Condenser...1109
Receiver drier ...1110
Sensor ...1111
Procedure for testing and troubleshooting...1112
Circuit diagram and arrangement of connector pins ...1114
System diagram ...1116
Parts and connectors layout...1118
Testing air leakage (duct) ...1121
Testing with self-diagnosis function ...1123
Testing vent (mode) changeover ...1125
Testing FRESH/RECIRC air changeover ...1126
Testing sunlight sensor...1127
Testing (dual) pressure switch for refrigerant ...1128
Testing relays ...1129
Troubleshooting chart 1...1130
Troubleshooting chart 2...1132
Information in troubleshooting table ...1134
Failure code list related to air conditioner...1135
Failure code [879AKA] A/C Inner sensor Open Circuit ...1136
Failure code [879AKB] A/C Inner sensor Short Circuit...1137
Failure code [879BKA] A/C Outer sensor Open Circuit...1138
Failure code [879BKB] A/C Outer sensor Short Circuit...1140
Failure code [879CKA] Ventilating sensor Open Circuit...1142
Failure code [879CKB] Ventilating sensor Short Circuit...1143
Failure code [879DKZ] Sunlight sensor Open or Short Circuit...1144
Failure code [879EMC] Ventilating Damper Abnormality ...1146
Failure code [879FMC] Air Mix Damper Abnormality...1147
Failure code [879GKX] Refrigerant Abnormality ...1148
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)...1150
Troubleshooting for compressor and refrigerant system (Air is not cooled)...1152
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...1155
Troubleshooting for FRESH/RECIRC air changeover...1157
Troubleshooting with gauge pressure ...1159
Connection of service tool...1161
Precautions for disconnecting and connecting air conditioner piping ...1163
Handling of compressor oil...1165
90 Diagrams and drawings...0
100 Hydraulic diagrams and drawings...1169
Symbols in hydraulic circuit diagram...1170
Hydraulic circuit diagram...1173
200 Electrical diagrams and drawings...1176
Symbols in electric circuit diagram...1177
Electrical circuit diagram...1180
