Complete service repair manual with Electrical Wiring Diagrams for Komatsu Logging/Road Builder Excavator Excavator GALEO PC300LC-7E0, PC300HD-7E0, PC300LL-7E0, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Logging/Road Builder Excavator Excavator GALEO PC300LC-7E0, PC300HD-7E0, PC300LL-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.

CEBM016802 - Hydraulic Excavator GALEO PC300LC-7E0, PC300HD-7E0 Shop Manual.pdf
CEBM017800 - Logging_Road Builder Excavator GALEO PC300LL-7E0 Shop Manual.pdf
CEAM016902 - Hydraulic Excavator GALEO PC300LL-7E0, PC300HD-7E0 Operation & Maintenance Manual.pdf
CEAM017802 - Logging Excavator GALEO PC300LL-7E0 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 2,466 pages
File Format: PDF
Language: English

CEAM016902 - Hydraulic Excavator GALEO PC300LL-7E0, PC300HD-7E0 Operation & Maintenance Manual...2
  COVER...2
  INTRODUCTION...4
    FOREWORD...5
    SAFETY INFORMATION...6
    INTRODUCTION...7
      INTENDED USE...7
      FEATURES...7
      DIRECTIONAL REFFERENCE OF MACHINE...7
      BREAKING IN A NEW MACHINE...8
      PLATE LOCATIONS...8
        PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...8
        ENGINE SERIAL NUMBER PLATE...9
        SERVICE METER LOCATION...9
      TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR...10
    TABLE OF CONTENTS...11
  SAFETY...20
    SAFETY AND WARNING DECALS...21
      LOCATION OF THE SAFETY DECALS...21
      SAFETY LABELS...22
    GENERAL SAFETY RULES AND PRECAUTIONS...28
      GENERAL SAFETY RULES...28
        UNAUTHORIZED MODIFICATIONS...29
        GENERAL SAFETY AT JOB SITE...29
        WORKING ON LOOSE GROUND...29
      SAFETY FEATURES...30
      PERSONAL PROTECTIVE EQUIPMENT...30
      FIRE AND EXPLOSION PREVENTION...31
        FIRE CAUSED BY FUEL OR OIL...31
        FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL...31
        FIRE COMING FROM ELECTRIC WIRING...32
        FIRE COMING FROM HYDRAULIC LINE...32
        WINDSHIELD WASHER FLUID...32
      ACTION IF FIRE OCCURS...32
      DUST HAZARD PRECAUTIONS...32
        ASBESTOS HAZARD ALERT...33
      KEEP OPERATOR'S COMPARTMENT CLEAN...33
      LEAVING OPERATOR'S SEAT WITH LOCK...33
      MOUNTING AND DISMOUNTING...34
      FIRE EXTINGUISHER AND FIRST AID KIT...34
      INSIDE OPERATOR’S COMPARTMENT...35
      PROTECTION AGAINST FALLING OR FLYING OBJECTS...35
      PRECAUTIONS FOR ATTACHMENTS...36
        QUICK COUPLER ATTACHMENT...36
        LARGE ATTACHMENTS AND COMBINATIONS...36
    PRECAUTIONS BEFORE STARTING OPERATIONS...37
      PRE-OPERATIONAL CHECKS...37
      STARTING YOUR WORK OPERATIONS...37
      WORK SITE HAZARDS...37
      AVOIDING DANGEROUS SITUATIONS...38
        DIGGING HARD ROCKY GROUND...41
        SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL...41
      WORKING CLEARANCES...42
      OPERATIONS ON SLOPES...43
      OPERATIONS ON SNOW...43
    RULES FOR ROAD TRAVEL...44
      TRAVELING WITH CARRAGE REVERSED...44
      TRAVEL ON SLOPES...45
      PARKING THE MACHINE...46
    PRECAUTIONS DURING MAINTENANCE OPERATIONS...47
      WARNING TAGS...47
      EQUIPMENT STORAGE...47
      WORKING UNDER THE MACHINE...48
      USING DROP LAMPS...48
      KEEPING THE MACHINE CLEAN...48
      PERFORMING GENERAL MAINTENANCE PROCEDURES...49
      RUNNING THE ENGINE DURING MAINTENANCE...50
      PROPER TOOLS...50
      WELDING, GRINDING OR CUTTING...51
      ADJUSTING TRACK TENSION...51
      DO NOT DISASSEMBLE RECOIL SPRINGS...51
      WHEN USING HAMMER...51
      RULES FOR REFUELING THE MACHINE...52
      COOLING SYSTEM PRECAUTIONS...52
      BATTERY PRECAUTIONS...53
        STARTING ENGINE WITH BOOSTER CABLES...53
      STARTING PRECAUTIONS...53
      HIGH PRESSURE HOSES...54
        SAFETY HANDLING HIGH-PRESSURE HOSES...54
      PRECAUTION FOR HIGH FUEL PRESSURE...54
      HIGH TEMPERATURES AREAS...54
      DISPOSAL OF WASTE MATERIALS...55
      ACCUMULATOR...55
      CRITICAL PARTS...55
      HIGH VOLTAGE...56
      TOWING...56
        SAFETY RULES FOR TOWING...56
  OPERATION...58
    GENERAL VIEWS...59
      VIEW OF MACHINE...59
      VIEW CONTROLS AND GAUGES...60
    MACHINE MONITOR SYSTEM...61
      MONITOR BEZEL LAYOUT...61
      BASIC OPERATION OF MACHINE MONITOR...62
        ABNORMALITY OCCURS WHEN STARTING THE ENGINE...63
        ABNORMALITY OCCURS DURING OPERATION...64
        COLOR WARNING OR ALERT SYSTEM...65
    MONITOR CHECK ITEMS...66
      EMERGENCY ALERTS...66
        ENGINE COOLANT TEMPERATURE MONITOR...66
        HYDRAULIC OIL TEMPERATURE MONITOR...67
        ENGINE OIL PRESSURE MONITOR...67
      WARNING ALERTS...68
        ENGINE COOLANT TEMPERATURE MONITOR...68
        HYDRAULIC OIL TEMPERATURE MONITOR...69
        FUEL LEVEL MONITOR...69
        CHARGE MONITOR...69
        AIR CLEANER CLOGGING MONITOR...69
        WATER SEPARATOR MONITOR...70
      CHECK ALERTS...71
        COOLANT LEVEL MONITOR...71
        ENGINE OIL LEVEL MONITOR...72
        MAINTENANCE INTERVAL MONITOR...72
      METER DISPLAY...73
        PILOT DISPLAYS...73
        GAUGES...76
    MONITOR SWITCHES...78
      SWITCH LAYOUT VIEW...78
        WORKING MODE SELECTOR SWITCH...79
        AUTO-DECELERATION SWITCH...80
        TRAVEL SPEED SELECTOR SWITCH...81
        WIPER SWITCH...82
        WINDOW WASHER SWITCH...82
        MAINTENANCE SWITCH...83
        SELECT SWITCH...85
        BACK SWITCH...87
        UP SWITCH, DOWN SWITCH...87
        INPUT CONFIRMATION SWITCH...88
        LIQUID CRYSTAL ADJUSTMENT SWITCH...88
        ALARM BUZZER STOP SWITCH...89
    CONSOLE CONTROL SWITCHES...90
      SWITCH LAYOUT VIEW...90
        IGNITION SWITCH...91
        ENGINE SPEED CONTROL DIAL...91
        CIGARETTE LIGHTER...91
        SWING LOCK SWITCH...92
        LAMP SWITCH...92
        MACHINE PUSH-UP SWITCH...92
        HORN SWITCH...93
        POWER MAX SWITCH...93
        CAB LAMP SWITCH...93
        EMERGENCY PUMP DRIVE SWITCH...93
        SWING BRAKE CANCEL SWITCH...94
    CONTROL LEVERS AND PEDALS...95
    LEVER LAYOUT VIEW...95
      SAFETY LOCK LEVER...95
      TRAVEL LEVERS...96
      WORK EQUIPMENT CONTROL LEVER...97
    WINDOW SYSTEM...98
      CEILING WINDOW...98
        WHEN OPENING...98
        WHEN CLOSING...98
      FRONT WINDOW...99
        WHEN OPENING...99
        WHEN CLOSING...101
        REMOVING FRONT BOTTOM WINDOW...103
      CAB EMERGENCY EXIT WINDOW...104
    SAFETY LOCKS AND SECURITY...105
      DOOR LOCK...105
      CAP, COVER WITH LOCK...105
        OPENING AND CLOSING CAP WITH LOCK...106
        OPENING AND CLOSING COVER...106
      LOCKABLE AREAS...106
    ADDTIONAL FEATURES AND ACCESSORIES...108
      HOT AND COOL BOX...108
      STORAGE BOX WITH CUP HOLDER...108
      ASHTRAY...108
      AUTO-TEMP AIR CONDITIONER...109
        GENERAL DESCRIPTION OF CONTROL PANEL...109
        SUNLIGHT SENSOR...113
        A/C SYSTEM OPERATION...113
        PRECAUTIONS WHEN USING AIR CONDITIONER...120
        MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER...120
        SELF-DIAGNOSTIC FUNCTION...120
      RADIO...122
        EXPLANATION OF FEATURES...122
        CONTROLS ON RADIO...124
      TOOLBOX...126
      GREASE GUN HOLDER...126
      AUXILIARY POWER PORTS...127
        24V POWER SOURCE...127
        12V POWER SOURCE (IF EQUIPPED)...127
    FUSES AND FUSE LINKS...128
      FUSES...128
        FUSE CAPACITIES AND CIRCUIT NAMES...128
      FUSIBLE LINK...129
    PRECAUTIONS BEFORE STARTING WORK OPERATIONS...130
      PRE-OPERATIONAL CHECKS...130
        WALK-AROUND CHECKS...130
        CHECKS BEFORE STARTING...131
        ADJUSTMENTS BEFORE OPERATION...137
        REARVIEW MIRRORS...138
        SEAT BELT...139
        SYSTEM “ON” CHECKS...140
      STARTING THE ENGINE...143
        NORMAL OR COLD START PROCEDURES...143
    OPERATIONS AND CHECKS AFTER STARTING ENGINE...146
      BREAKING IN THE MACHINE...146
        WARMING UP ENGINE...146
        WARMING UP HYDRAULIC EQUIPMENT...148
        AFTER WARMING-UP OPERATIONS...152
      STOPPING THE ENGINE...153
        CHECK AFTER SHUTING OFF ENGINE...153
    MOVING, STOPPING AND PARKING THE MACHINE...154
      PREPARATIONS FOR MOVING THE MACHINE...154
      TURNING THE MACHINE...155
        TURNING THE MACHINE WHEN STOPPED...155
        CHANGING DIRECTION OF THE MACHINE...156
        COUNTER-ROTATION TURN (SPIN TURN)...157
      SWINGING...157
      GENERAL TRAVELING...158
        TRAVELING OVER OBSTACLES...158
        HIGH SPEED TRAVEL...158
        PERMISSIBLE WATER DEPTH...158
        TRAVELING ON SLOPES...159
        TRAVELING DOWNHILL...160
        ENGINE STOPPED ON SLOPE...160
        PRECAUTIONS ON SLOPES...160
        ESCAPING FROM MUD...160
        ONE SIDE OF TRACK STUCK...161
        BOTH SIDES OF TRACKS STUCK...161
        MOVING MACHINE BACKWARD...161
      STOPPING MACHINE...162
      PARKING MACHINE...163
        CLEARING THE MACHINES TRACKS...163
        PARKING...163
        MACHINE INSPECTION AFTER DAILY WORK...165
    STARTING YOUR WORK OPERATIONS...166
      AVOIDING DANGEROUS SITUATIONS...166
        DIGGING HARD ROCKY GROUND...169
        SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL...169
      WORKING CLEARANCES...170
      OPERATIONS ON SLOPES...170
      OPERATIONS ON SNOW...171
      WORK EQUIPMENT OVERVIEW...172
        ARM CONTROL...172
        SWING CONTROL...172
        BOOM CONTROL...172
        BUCKET CONTROL...172
      OPERATING MODES...173
        WORKING MODE...173
        ONE-TOUCH POWER MAX. SWITCH...173
      EXCAVATING PROCEDURES...174
        WORK EQUIPMENT ANGLES...175
        DITCHING WORK...175
        LOADING WORK...175
        SEVERE JOB CONDITIONS...175
    REPLACING WORK IMPLEMENTS...176
      BUCKET REPLACEMENT...176
    TRANSPORTING THE MACHINE...178
      LOADING AND UNLOADING A TRAILER...178
        LOADING THE MACHINE...179
        SECURING MACHINE...182
        UNLOADING THE MACHINE...184
      LIFTING THE MACHINE...186
      TOWING THE MACHINE...188
        LIGHTWEIGHT TOWING HOOK...188
    COLD WEATHER OPERATION...189
      FUEL AND LUBRICANTS...189
      COOLING SYSTEM COOLANT...189
      BATTERY...190
      MONITOR...191
      PRECAUTIONS ON PARTICULAR JOBSITES...192
      DISCHARGED BATTERY...192
        REMOVAL AND INSTALLATION OF BATTERY...193
        BATTERY CHARGES...193
        STARTING ENGINE WITH BOOSTER CABLES...194
    GENERAL TROUBLESHOOTING...196
      AFTER RUNNING OUT OF FUEL...196
        PROCEDURE FOR BLEEDING AIR...196
      PHENOMENA THAT ARE NOT FAILURES...196
      ELECTRICAL SYSTEM PROBLEMS...197
      CHASSIS PROBLEMS...198
      ENGINE PROBLEMS...199
      ELECTRONIC CONTROL SYSTEM...200
        MACHINE MONITOR TROUBLE DISPLAY...200
      TELEPHONE WHEN ERROR OCCURS...201
    LONG TERM STORAGE...202
      BEFORE STORAGE...202
      DURING STORAGE...202
      AFTER STORAGE...202
        STARTING MACHINE...202
  MAINTENANCE...204
    MAINTENANCE INFORMATION...205
      SERVICE METER READING...205
      KOMATSU GENUINE REPLACEMENT PARTS...205
      KOMATSU GENUINE LUBRICANTS...205
      WINDSHIELD WASHER FLUID...205
      FRESH AND CLEAN LUBRICANTS...205
      CHECK DRAINED OIL AND USED FILTER...205
      FUEL STRAINER...205
      WELDING INSTRUCTIONS...205
      DO NOT DROP THINGS INSIDE MACHINE...205
      SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE...205
      DUSTY JOBSITE...206
      AVOID MIXING LUBRICANTS...206
      LOCKING THE INSPECTION COVERS...206
      HYDRAULIC SYSTEM - AIR BLEEDING...206
      HYDRAULIC HOSE INSTALLATION...206
      CHECKS AFTER INSPECTION AND MAINTENANCE WORKS...206
    LUBRICANTS, COOLANT AND FILTERS...207
      OUTLINE OF SERVICE...207
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...207
        OIL...207
        FUEL...208
        COOLANT AND WATER FOR DILUTION...208
        GREASE...208
        CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)...209
        OIL AND FUEL STORAGE...209
        FILTERS...210
      ELECTRIC SYSTEM MAINTENANCE...211
      HANDLING HYDRAULIC SYSTEM...211
    WEAR PARTS LIST...212
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT...213
      RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS...215
    TIGHTENING TORQUE SPECIFICATIONS...216
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...217
      SAFETY RELATED CRITICAL PARTS...218
    MAINTENANCE SCHEDULE...219
      MAINTENANCE SCHEDULE CHART...219
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...221
        REPLACE HYDRAULIC FILTER ELEMENT...221
        CHANGE OIL IN HYDRAULIC TANK...221
        REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER (IF EQUIPPED)...221
    MAINTENANCE PROCEDURE...222
      INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)...222
      WHEN REQUIRED...223
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...223
        CLEAN INSIDE OF COOLING SYSTEM...228
        CHECK AND TIGHTEN TRACK SHOE BOLTS...231
        CHECK AND ADJUST TRACK TENSION...232
        REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...234
        REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...237
        REPLACE BUCKET SIDE CUTTER, SHROUD...238
        ADJUST BUCKET CLEARANCE...239
        CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...240
        CHECK AND ADJUST AIR CONDITIONER...241
        CLEANING CAB FLOOR...242
        SETTING MACHINE AT AN ANGLE...244
        BLEEDING AIR FROM HYDRAULIC SYSTEM...245
      CHECK BEFORE STARTING...247
      EVERY 50 HOURS MAINTENANCE...248
        LUBRICATING...248
      EVERY 250 HOURS MAINTENANCE...249
        LUBRICATE SWING CIRCLE...249
        CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL...249
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...250
        CHECK LEVEL OF BATTERY ELECTROLYTE...251
        CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...253
      EVERY 500 HOURS MAINTENANCE...254
        LUBRICATING...254
        REPLACE FUEL PRE-FILTER CARTRIDGE...255
        CHECK SWING PINION GREASE LEVEL, ADD GREASE...258
        CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTER CARTRIDGE...259
        CLEAN/INSPECT RADIATOR, OIL COOLER, AFTERCOOLER AND CONDENSER FINS...260
        CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...262
        REPLACE VENT ELEMENT IN HYDRAULIC TANK...263
      EVERY 1000 HOURS MAINTENANCE...264
        REPLACE FUEL MAIN FILTER CARTRIDGE...264
        REPLACE HYDRAULIC OIL FILTER ELEMENT...266
        CHANGE OIL IN SWING MACHINERY CASE...267
        CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...268
        CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS...268
        REPLACE CORROSION RESISTOR CARTRIDGE (IF EQUIPPED)...269
        CHECK FAN BELT AND ALTERNATOR DRIVE BELT TENSION, REPLACE...269
        REPLACE HYDRAULIC TANK ADDITIONAL VENT ELEMENT...270
        CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)...270
      EVERY 2000 HOURS MAINTENANCE...271
        CHANGE OIL IN FINAL DRIVE CASE...271
        CLEAN HYDRAULIC TANK STRAINER...272
        CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)...273
        CHECKING FUNCTION OF ACCUMULATOR...274
        RELEASING PRESSURE IN HYDRAULIC CIRCUIT...275
        CHECK ALTERNATOR, STARTING MOTOR...276
        CHECK ENGINE VALVE CLEARANCE, ADJUST...276
        CHECK VIBRATION DAMPER...276
      EVERY 4000 HOURS MAINTENANCE...277
        CHECK WATER PUMP...277
        CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)...278
        CHECK HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER...279
        CHECK FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...279
      EVERY 5000 HOURS MAINTENANCE...280
        CHANGE OIL IN HYDRAULIC TANK...280
      EVERY 8000 HOURS MAINTENANCE...281
        REPLACE HIGH-PRESSURE PIPING CLAMP...281
        REPLACE FUEL SPRAY PREVENTION CAP...281
  SPECIFICATIONS...284
    SPECIFICATIONS...285
  OPTIONS, ATTACHMENTS...288
    GENERAL PRECAUTIONS...289
      PRECAUTIONS RELATED TO SAFETY...289
      PRECAUTIONS FOR ATTACHMENT REMOVAL AND INSTALLATION...289
      PRECAUTIONS WHEN USING LARGE IMPLEMENTS...290
      HANDLING BUCKET WITH HOOK...291
        HOOK CONDITION...291
        PROHIBITED OPERATIONS...291
    MACHINES READY FOR ATTACHMENTS...292
      EXPLANATION OF COMPONENTS...292
        STOP VALVE...292
        SELECTOR VALVE...293
        ATTACHMENT CONTROL PEDAL...293
        LOCK PIN...293
        BREAKER CIRCUIT ADDITIONAL OIL FILTER...294
      HYDRAULIC CIRCUIT...296
        SWITCHING THE HYDRAULIC CIRCUIT...296
        ADJUSTING OIL FLOW...296
        SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT...296
        HYDRAULIC CIRCUIT CONNECTION...297
        OIL FLOW...298
        REPLACE ADDITIONAL BREAKER FILTER ELEMENT...299
      ATTACHMENT INSTALLATION AND REMOVAL PROCEDURE...300
        REMOVAL PROCEDURE...300
        INSTALLATION PROCEDURE...301
      ATTACHMENT OPERATIONS...302
        WHEN USING BREAKER...302
        WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER...302
      LONG TERM STORAGE...303
      SPECIFICATIONS...303
    ATTACHMENT GUIDE...304
      COMBINATIONS OF WORK EQUIPMENT...304
      SELECTION OF TRACK SHOES...306
        SELECTING SHOES...306
    HYDRAULIC BREAKER...307
      MAIN APPLICATIONS...307
        PROHIBITED OPERATIONS...309
        GREASING...311
CEAM017802 - Logging Excavator GALEO PC300LL-7E0 Operation & Maintenance Manual...312
  COVER...312
  INTRODUCTION...316
    FOREWORD...317
    SAFETY INFORMATION...318
    INTRODUCTION...319
      INTENDED USE...319
      FEATURES...319
      DIRECTIONAL REFFERENCE OF MACHINE...319
      BREAKING IN A NEW MACHINE...320
      PLATE LOCATIONS...320
        PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...320
      KOMATSU FORESTRY FRONT S/N PLATE...321
        ENGINE SERIAL NUMBER PLATE...322
        SERVICE METER LOCATION...322
      TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR...323
    TABLE OF CONTENTS...324
  SAFETY...334
    SAFETY AND WARNING DECALS...335
      NORMAL EXCAVATOR DECALS...335
      SAFETY LABELS...336
      UNIQUE SAFETY DECALS FOR LOG LOADER AND ROAD BUILDER EXCAVATORS...342
    GENERAL SAFETY RULES AND PRECAUTIONS...347
      GENERAL SAFETY RULES...347
        UNAUTHORIZED MODIFICATIONS...348
        GENERAL SAFETY AT JOB SITE...348
        WORKING ON LOOSE GROUND...348
      SAFETY FEATURES...349
      PERSONAL PROTECTIVE EQUIPMENT...349
      FIRE AND EXPLOSION PREVENTION...349
        FIRE CAUSED BY FUEL OR OIL...350
        FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL...350
        FIRE COMING FROM ELECTRIC WIRING...351
        FIRE COMING FROM HYDRAULIC LINE...351
        WINDSHIELD WASHER FLUID...351
      ACTION IF FIRE OCCURS...351
      DUST HAZARD PRECAUTIONS...351
        ASBESTOS HAZARD ALERT...352
      KEEP OPERATOR'S COMPARTMENT CLEAN...352
      LEAVING OPERATOR'S SEAT WITH LOCK...352
      MOUNTING AND DISMOUNTING...353
      FIRE EXTINGUISHER AND FIRST AID KIT...353
      INSIDE OPERATOR’S COMPARTMENT...354
      PROTECTION AGAINST FALLING OR FLYING OBJECTS...354
      PRECAUTIONS FOR ATTACHMENTS...355
        QUICK COUPLER ATTACHMENT...355
        LARGE ATTACHMENTS AND COMBINATIONS...355
    PRECAUTIONS BEFORE STARTING OPERATIONS...356
      PRE-OPERATIONAL CHECKS...356
      STARTING YOUR WORK OPERATIONS...356
      WORK SITE HAZARDS...356
      AVOIDING DANGEROUS SITUATIONS...357
        DIGGING HARD ROCKY GROUND...360
        SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL...360
      WORKING CLEARANCES...361
      OPERATIONS ON SLOPES...362
      OPERATIONS ON SNOW...362
    RULES FOR ROAD TRAVEL...363
      TRAVELING WITH CARRAGE REVERSED...363
      TRAVEL ON SLOPES...364
      SHIPPING THE MACHINE...365
      PARKING THE MACHINE...366
    PRECAUTIONS DURING MAINTENANCE OPERATIONS...367
      WARNING TAGS...367
      EQUIPMENT STORAGE...367
      WORKING UNDER THE MACHINE...368
      USING DROP LAMPS...368
      KEEPING THE MACHINE CLEAN...368
      PERFORMING GENERAL MAINTENANCE PROCEDURES...369
      RUNNING THE ENGINE DURING MAINTENANCE...370
      PROPER TOOLS...370
      WELDING, GRINDING OR CUTTING...371
      ADJUSTING TRACK TENSION...371
      DO NOT DISASSEMBLE RECOIL SPRINGS...371
      WHEN USING HAMMER...371
      RULES FOR REFUELING THE MACHINE...372
      COOLING SYSTEM PRECAUTIONS...372
      BATTERY PRECAUTIONS...373
        STARTING ENGINE WITH BOOSTER CABLES...373
      STARTING PRECAUTIONS...373
      HIGH PRESSURE HOSES...374
        SAFETY HANDLING HIGH-PRESSURE HOSES...374
      PRECAUTION FOR HIGH FUEL PRESSURE...374
      HIGH TEMPERATURES AREAS...375
      DISPOSAL OF WASTE MATERIALS...375
      ACCUMULATOR...375
      CRITICAL PARTS...376
      HIGH VOLTAGE...376
      TOWING...376
        SAFETY RULES FOR TOWING...376
  OPERATION...378
    GENERAL VIEWS...379
      GENERAL VIEW OF LOG LOADER MACHINE...379
      GENERAL VIEW OF ROAD BUILDER MACHINE...380
      VIEW CONTROLS AND GAUGES...381
    MACHINE MONITOR SYSTEM...382
      MONITOR LAYOUT...382
      BASIC OPERATION OF MACHINE MONITOR...383
        ABNORMALITY OCCURS WHEN STARTING THE ENGINE...384
        ABNORMALITY OCCURS DURING OPERATION...385
        COLOR WARNING OR ALERT SYSTEM...386
    MONITOR CHECK ITEMS...387
      EMERGENCY ALERTS...387
        ENGINE COOLANT TEMPERATURE MONITOR...387
        HYDRAULIC OIL TEMPERATURE MONITOR...388
        ENGINE OIL PRESSURE MONITOR...388
      WARNING ALERTS...389
        ENGINE COOLANT TEMPERATURE MONITOR...389
        HYDRAULIC OIL TEMPERATURE MONITOR...390
        FUEL LEVEL MONITOR...390
        CHARGE MONITOR...390
        AIR CLEANER CLOGGING MONITOR...390
        WATER SEPARATOR MONITOR...391
      CHECK ALERTS...392
        COOLANT LEVEL MONITOR...392
        ENGINE OIL LEVEL MONITOR...393
        MAINTENANCE INTERVAL MONITOR...393
      METER DISPLAY...394
        PILOT DISPLAYS...394
        GAUGES...397
    MONITOR SWITCHES...399
      SWITCH LAYOUT VIEW...399
        WORKING MODE SELECTOR SWITCH...400
        AUTO-DECELERATION SWITCH...401
        TRAVEL SPEED SELECTOR SWITCH...402
        WIPER SWITCH...403
        WINDOW WASHER SWITCH...403
        MAINTENANCE SWITCH...404
        SELECT SWITCH...406
        BACK SWITCH...408
        UP SWITCH, DOWN SWITCH...408
        INPUT CONFIRMATION SWITCH...409
        LIQUID CRYSTAL ADJUSTMENT SWITCH...409
        ALARM BUZZER STOP SWITCH...410
    CONSOLE CONTROL SWITCHES...411
      SWITCH LAYOUT VIEW...411
        IGNITION SWITCH...413
        ENGINE SPEED CONTROL DIAL...413
        CIGARETTE LIGHTER...413
        SWING LOCK SWITCH...414
        LAMP SWITCH...414
        MACHINE PUSH-UP SWITCH...414
        HORN SWITCH...415
        LOG LOADER GRAPPLE ROTATION CW SWITCH...415
        LOG LOADER GRAPPLE CLOSE SWITCH...415
        POWER MAX SWITCH...415
        LOG LOADER GRAPPLE ROTATION CCW SWITCH...415
        LOG LOADER GRAPPLE OPEN SWITCH...415
        CAB LAMP SWITCH...416
        EMERGENCY PUMP DRIVE SWITCH...416
        SWING BRAKE CANCEL SWITCH...416
    CONTROL LEVERS AND PEDALS...417
    LEVER LAYOUT VIEW...417
      SAFETY LOCK LEVER...418
      TRAVEL LEVERS...418
      WORK EQUIPMENT CONTROL LEVER...419
    WINDOW SYSTEM...420
      CEILING WINDOW...420
        WHEN OPENING...420
        WHEN CLOSING...420
      FRONT WINDOW...421
        WHEN OPENING...421
        WHEN CLOSING...424
        REMOVING FRONT BOTTOM WINDOW...425
      CAB EMERGENCY EXIT WINDOW...426
    SAFETY LOCKS AND SECURITY...427
      DOOR LOCK...427
      CAP, COVER WITH LOCK...427
        OPENING AND CLOSING CAP WITH LOCK...428
        OPENING AND CLOSING COVER...428
      LOCKABLE AREAS...429
    ADDTIONAL FEATURES AND ACCESSORIES...430
      HOT AND COOL BOX...430
      STORAGE BOX WITH CUP HOLDER...430
      ASHTRAY...430
      AUTO-TEMP AIR CONDITIONER...431
        GENERAL DESCRIPTION OF CONTROL PANEL...431
        SUNLIGHT SENSOR...435
        A/C SYSTEM OPERATION...435
        PRECAUTIONS WHEN USING AIR CONDITIONER...442
        MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER...442
        SELF-DIAGNOSTIC FUNCTION...442
      RADIO...444
        EXPLANATION OF FEATURES...444
        CONTROLS ON RADIO...446
      TOOLBOX...448
      GREASE GUN HOLDER...448
      AUXILIARY POWER PORTS...449
        24V POWER SOURCE...449
        12V POWER SOURCE (IF EQUIPPED)...449
    FUSES AND FUSE LINKS...450
      FUSES...450
        FUSE CAPACITIES AND CIRCUIT NAMES...450
      FUSIBLE LINK...451
    HANDLING THE ACCUMULATOR...452
      RELEASING PRESSURE IN CONTROL CIRCUIT...452
    PRECAUTIONS BEFORE STARTING WORK OPERATIONS...453
      PRE-OPERATIONAL CHECKS...453
        WALK-AROUND CHECKS...453
        CHECKS BEFORE STARTING...454
        ADJUSTMENTS BEFORE OPERATION...461
        REAR VIEW MIRRORS...462
        SEAT BELT...463
        SYSTEM “ON” CHECKS...464
      STARTING THE ENGINE...467
        NORMAL OR COLD START PROCEDURES...467
    OPERATIONS AND CHECKS AFTER STARTING ENGINE...470
      BREAKING IN THE MACHINE...470
        WARMING UP ENGINE...470
        WARMING UP HYDRAULIC EQUIPMENT...472
        AFTER WARMING-UP OPERATIONS...477
      STOPPING THE ENGINE...478
        CHECK AFTER SHUTING OFF ENGINE...478
    MOVING, STOPPING AND PARKING THE MACHINE...479
      PREPARATIONS FOR MOVING THE MACHINE...479
      MOVING MACHINE...480
      TURNING THE MACHINE...481
        TURNING THE MACHINE WHEN STOPPED...481
        CHANGING DIRECTION OF THE MACHINE...482
        COUNTER-ROTATION TURN (SPIN TURN)...482
      SWINGING...483
      GENERAL TRAVELING...484
        TRAVELING OVER OBSTACLES...484
        HIGH SPEED TRAVEL...484
        PERMISSIBLE WATER DEPTH...484
        TRAVELING ON SLOPES...485
        TRAVELING DOWNHILL...486
        ENGINE STOPPED ON SLOPE...486
        PRECAUTIONS ON SLOPES...486
        ESCAPING FROM MUD...486
        ONE SIDE OF TRACK STUCK...486
        BOTH SIDES OF TRACKS STUCK...487
        MOVING MACHINE BACKWARD...487
      STOPPING MACHINE...488
      PARKING MACHINE...489
        CLEARING THE MACHINES TRACKS...489
        PARKING...490
        MACHINE INSPECTION AFTER DAILY WORK...492
    STARTING YOUR WORK OPERATIONS...493
      AVOIDING DANGEROUS SITUATIONS...493
        DIGGING HARD ROCKY GROUND...496
        SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL...496
      WORKING CLEARANCES...497
      OPERATIONS ON SLOPES...497
      OPERATIONS ON SNOW...498
      WORK EQUIPMENT OVERVIEW...499
        ARM CONTROL...499
        SWING CONTROL...499
        BOOM CONTROL...499
        BUCKET OR HEEL RACK CONTROL...499
      OPERATING MODES...500
        WORKING MODE...500
        ONE-TOUCH POWER MAX. SWITCH...500
      EXCAVATING PROCEDURES...501
        WORK EQUIPMENT ANGLES...501
        DITCHING WORK...501
        LOADING WORK...502
        SEVERE JOB CONDITIONS...502
    REPLACING WORK IMPLEMENTS...503
      BUCKET REPLACEMENT...503
    TRANSPORTING THE MACHINE...505
      LOADING AND UNLOADING A TRAILER...505
        LOADING THE MACHINE...506
        SECURING MACHINE...510
        UNLOADING THE MACHINE...514
      LIFTING THE MACHINE...517
      TOWING THE MACHINE...519
        LIGHTWEIGHT TOWING HOOK...519
    COLD WEATHER OPERATION...520
      FUEL AND LUBRICANTS...520
      COOLING SYSTEM COOLANT...520
      BATTERY...521
      MONITOR...522
      PRECAUTIONS ON PARTICULAR JOBSITES...523
      DISCHARGED BATTERY...523
        REMOVAL AND INSTALLATION OF BATTERY...524
        BATTERY CHARGES...524
        STARTING ENGINE WITH BOOSTER CABLES...525
    GENERAL TROUBLESHOOTING...527
      AFTER RUNNING OUT OF FUEL...527
        PROCEDURE FOR BLEEDING AIR...527
      PHENOMENA THAT ARE NOT FAILURES...527
      ELECTRICAL SYSTEM PROBLEMS...528
      CHASSIS PROBLEMS...529
      ENGINE PROBLEMS...530
      ELECTRONIC CONTROL SYSTEM...531
        MACHINE MONITOR TROUBLE DISPLAY...531
      TELEPHONE WHEN ERROR OCCURS...532
    LONG TERM STORAGE...533
      BEFORE STORAGE...533
      DURING STORAGE...533
      AFTER STORAGE...534
        STARTING MACHINE...534
  MAINTENANCE...536
    MAINTENANCE INFORMATION...537
      SERVICE METER READING...537
      KOMATSU GENUINE REPLACEMENT PARTS...537
      KOMATSU GENUINE LUBRICANTS...537
      WINDSHIELD WASHER FLUID...537
      FRESH AND CLEAN LUBRICANTS...537
      CHECK DRAINED OIL AND USED FILTER...537
      FUEL STRAINER...537
      WELDING INSTRUCTIONS...537
      DO NOT DROP THINGS INSIDE MACHINE...537
      SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE...537
      DUSTY JOBSITE...538
      AVOID MIXING LUBRICANTS...538
      LOCKING THE INSPECTION COVERS...538
      HYDRAULIC SYSTEM - AIR BLEEDING...538
      HYDRAULIC HOSE INSTALLATION...538
      CHECKS AFTER INSPECTION AND MAINTENANCE WORKS...538
    LUBRICANTS, COOLANT AND FILTERS...539
      OUTLINE OF SERVICE...539
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...539
        OIL...539
        FUEL...540
        COOLANT AND WATER FOR DILUTION...540
        GREASE...540
        CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)...541
        OIL AND FUEL STORAGE...541
        FILTERS...542
      ELECTRIC SYSTEM MAINTENANCE...542
      HANDLING HYDRAULIC SYSTEM...542
    WEAR PARTS LIST...543
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT...544
      RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS...546
    TIGHTENING TORQUE SPECIFICATIONS...547
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...548
      SAFETY RELATED CRITICAL PARTS...549
    MAINTENANCE SCHEDULE...550
      MAINTENANCE SCHEDULE CHART...550
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...552
        REPLACE HYDRAULIC FILTER ELEMENT...552
        CHANGE OIL IN HYDRAULIC TANK...552
        REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER (IF EQUIPPED)...552
    MAINTENANCE PROCEDURE...553
      INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)...553
      WHEN REQUIRED...554
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...554
        CLEAN INSIDE OF COOLING SYSTEM...559
        CHECK AND TIGHTEN TRACK SHOE BOLTS...562
        CHECK AND ADJUST TRACK TENSION...563
        REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...565
        REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...568
        REPLACE BUCKET SIDE CUTTER, SHROUD...569
        ADJUST BUCKET CLEARANCE...570
        CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...571
        CHECK AND ADJUST AIR CONDITIONER...572
        CLEANING CAB FLOOR...573
        SETTING MACHINE AT AN ANGLE...575
        BLEEDING AIR FROM HYDRAULIC SYSTEM...576
      CHECK BEFORE STARTING...578
      EVERY 50 HOURS MAINTENANCE...579
        LUBRICATING ROAD BUILDER...579
      EVERY 250 HOURS MAINTENANCE...581
        LUBRICATE SWING CIRCLE...581
        CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL...581
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...582
        CHECK LEVEL OF BATTERY ELECTROLYTE...583
        CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...585
      EVERY 500 HOURS MAINTENANCE...586
        LUBRICATING...586
        REPLACE FUEL PRE-FILTER CARTRIDGE...587
        CHECK SWING PINION GREASE LEVEL, ADD GREASE...590
        CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTER CARTRIDGE...591
        CLEAN/NSPECT RADIATOR, OIL COOLER, AFTERCOOLER AND CONDENSER FINS...592
        CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...594
        REPLACE VENT ELEMENT IN HYDRAULIC TANK...595
      EVERY 1000 HOURS MAINTENANCE...596
        REPLACE FUEL MAIN FILTER CARTRIDGE...596
        REPLACE HYDRAULIC OIL FILTER ELEMENT...598
        CHANGE OIL IN SWING MACHINERY CASE...599
        CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...600
        CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS...600
        REPLACE CORROSION RESISTOR CARTRIDGE...601
        CHECK FAN BELT AND ALTERNATOR DRIVE BELT TENSION, REPLACE...601
        REPLACE HYDRAULIC TANK ADDITIONAL VENT ELEMENT...602
        CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)...602
      EVERY 2000 HOURS MAINTENANCE...603
        CHANGE OIL IN FINAL DRIVE CASE...603
        CLEAN HYDRAULIC TANK STRAINER...604
        CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)...605
        CHECKING FUNCTION OF ACCUMULATOR...606
        RELEASING PRESSURE IN HYDRAULIC CIRCUIT...607
        CHECK ALTERNATOR, STARTING MOTOR...608
        CHECK ENGINE VALVE CLEARANCE, ADJUST...608
        CHECK VIBRATION DAMPER...608
      EVERY 4000 HOURS MAINTENANCE...609
        CHECK WATER PUMP...609
        REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)...610
        CHECK HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER...611
        CHECK FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...611
      EVERY 5000 HOURS MAINTENANCE...612
        CHANGE OIL IN HYDRAULIC TANK...612
      EVERY 8000 HOURS MAINTENANCE...613
        REPLACE HIGH-PRESSURE PIPING CLAMP...613
        REPLACE FUEL SPRAY PREVENTION CAP...613
  SPECIFICATIONS...614
    SPECIFICATIONS...615
      DIMENSIONS...615
      WORKING RANGE...619
        ROAD BUILDER...619
        LOG LOADER...621
      LIFTING CAPACITY...623
  OPTIONS, ATTACHMENTS...630
    GENERAL PRECAUTIONS...631
      PRECAUTIONS RELATED TO SAFETY...631
      PRECAUTIONS FOR ATTACHMENT REMOVAL AND INSTALLATION...631
      PRECAUTIONS WHEN USING LARGE IMPLEMENTS...632
      HANDLING BUCKET WITH HOOK...633
        HOOK CONDITION...633
        PROHIBITED OPERATIONS...633
    COMBINATIONS OF WORK EQUIPMENT FOR PC300LC-7...634
    SELECTION OF TRACK SHOES...635
CEBM016802 - Hydraulic Excavator GALEO PC300LC-7E0, PC300HD-7E0 Shop Manual...638
  COVER...638
  FOREWARD...639
    CONTENTS...639
    SAFETY...648
      SAFETY NOTICE...648
        IMPORTANT SAFETY NOTICE...648
        GENERAL PRECAUTIONS...648
        PREPARATIONS FOR WORK...648
        PRECAUTIONS DURING WORK...648
    GENERAL...650
    HOW TO READ THE SHOP MANUAL...651
      VOLUMES...651
      DISTRIBUTION AND UPDATING...651
      FILING METHOD...651
      REVISED EDITION MARK...651
      REVISIONS...651
      SYMBOLS...651
    HOISTING INSTRUCTIONS...652
      HOISTING...652
      WIRE ROPES...652
    PUSH PULL COUPLER...653
      TYPE 1...653
        DISCONNECTION...653
        CONNECTION...653
      TYPE 2...654
        DISCONNECTION...654
        CONNECTION...654
      TYPE 3...655
        DISCONNECTION...655
        CONNECTION...655
    EXPLANATION OF MAINTENANCE STANDARD TERMS...656
    STANDARD TIGHTENING TORQUE...658
      BOLTS AND NUTS...658
      TIGHTENING TORQUE OF HOSE NUTS...659
      TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...659
      TIGHTENING TORQUE FOR FLARED NUTS...659
      TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS...660
      TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS...660
      TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)...660
    ELECTRIC WIRE CODE...661
      CLASSIFICATION BY THICKNESS...661
      CLASSIFICATION BY COLOR AND CODE...661
      HOW TO READ ELECTRIC WIRE CODE...662
    CONVERSION TABLES...665
      METHOD OF USING THE CONVERSION TABLE...665
    COATING MATERIALS...671
  01 GENERAL...673
    SPECIFICATIONS...674
      DIMENSIONS...674
      WORKING RANGES...675
    SPECIFICATIONS...676
    WEIGHT TABLE...678
    FUEL, COOLANT, AND LUBRICANTS...680
  10 STRUCTURE AND FUNCTION...682
    ENGINE RELATED PARTS...687
    RADIATOR . OIL COOLER . AFTERCOOLER...688
    FINAL DRIVE...690
      PC300LC-7E0 MODEL...690
      PC300HD-7E0 MODEL...692
    SPROCKET...694
      PC300LC-7E0 MODEL...694
      SPROCKET TOOL...695
      PC300HD-7E0 MODEL...696
      SPROCKET TOOL...697
    SWING MACHINERY...698
      SWING CIRCLE...700
    TRACK FRAME . RECOIL SPRING...701
      PC300LC-7E0...701
      PC300HD-7E0...703
    IDLER...705
      PC300LC-7E0 MODEL...705
      PC300HD-7E0 MODEL...707
    CARRIER ROLLER...709
      PC300LC-7E0 MODEL...709
      PC300HD-7E0 MODEL...711
    TRACK ROLLER...713
      PC300LC-7E0 MODEL...713
      PC300HD-7E0 MODEL...715
    TRACK SHOE...717
      PC300LC-7E0 MODEL...717
      PC300HD-7E0 MODEL...720
    TRIPLE GROUSER SHOE...723
      PC300LC-7E0 MODEL...723
      PC300HD-7E0 MODEL...724
    HYDRAULIC EQUIPMENT...725
    HYDRAULIC TANK AND FILTER...727
    HYDRAULIC PUMP...728
      HPV125 + 125...728
        FUNCTION...731
        STRUCTURE...731
        OPERATION...732
      LS VALVE...734
        FUNCTION...734
        OPERATION...735
      PC VALVE...739
        FUNCTION...739
        OPERATION...740
        OUTLINE...742
        OPERATION...742
      LS(PC)-EPC Valve...746
        FUNCTION...747
        OPERATION...747
      VARIABLE VOLUME VALVE...749
        FUNCTION...749
        OPERATION...749
    CONTROL VALVE...750
      OUTLINE...750
    CLSS...762
      OUTLINE OF CLSS...762
      FEATURES...762
      STRUCTURE...762
      BASIC PRINCIPLE...763
      VALVE FUNCTIONS AND OPERATION...766
    UNLOADER VALVE...768
      FUNCTION...768
      OPERATION...768
      INTRODUCTION OF LS PRESSURE...770
        FUNCTION...770
        OPERATION...770
    LS BYPASS VALVE...771
      FUNCTION...771
    PRESSURE COMPENSATION VALVE...772
      FUNCTION...772
      FUNCTION...773
      OPERATION...773
      FUNCTION...774
      PRESSURE COMPENSATION VALVE INNER SHUTTLE...775
        FUNCTION...775
        OUTLINE...776
      BOOM REGENERATION CIRCUIT...777
        FUNCTION...777
        OPERATION...777
        FUNCTION...778
      ARM REGENERATION CIRCUIT...779
        FUNCTION...779
        OPERATION...779
        FUNCTION...780
    MERGE-DIVIDER VALVE...781
      FUNCTION...781
      OPERATION...781
      OPERATION...782
    LS SELECT VALVE...783
      FUNCTION...783
      OPERATION...783
    SELF PRESSURE REDUCING VALVE...784
      FUNCTION...784
      OPERATION...784
    TRAVEL JUNCTION VALVE...787
      FUNCTION...787
      OPERATION...787
      OPERATION...788
    TRAVEL PPC SHUTTLE VALVE...789
      FUNCTION...789
      OPERATION...789
      OPERATION...790
    BOOM DRIFT PREVENTION VALVE...791
      FUNCTION...791
      OPERATION...791
      OPERATION...792
      OPERATION...793
    ARM DRIFT PREVENTION VALVE...794
      FUNCTION...794
      OPERATION...794
      OPERATION...795
      OPERATION...796
    QUICK RETURN VALVE...798
      FUNCTION...798
      OPERATION...798
      OPERATION...799
    LIFT CHECK VALVE...800
      FUNCTION...800
      OPERATION...800
    MAIN RELIEF VALVE...801
      FUNCTION...801
      OPERATION...801
    2-STAGE SAFETY-SUCTION VALVE...802
      FUNCTION...802
      OPERATION...802
    VARIABLE PRESSURE COMPENSATION VALVE...804
      FUNCTION...804
    ATTACHMENT CIRCUIT SELECTOR VALVE...806
      FUNCTION...807
      OPERATION...807
    VALVE CONTROL...808
    PPC VALVE...809
      WORK EQUIPMENT AND SWING PPC VALVE...809
        OPERATION...811
      TRAVEL PPC VALVE...813
    PRESSURE REDUCING VALVE...816
      OPERATION...816
      OPERATION...818
      SERVICE PPC VALVE...822
      PPC ACCUMULATOR...824
    SOLENOID VALVE...825
      OPERATION...826
    RETURN OIL FILTER...827
      FOR BREAKER...827
    CENTER SWIVEL JOINT...828
    TRAVEL MOTOR...829
      TYPE: HMV160ADT-3...829
      OPERATION OF MOTOR...832
    PARKING BRAKE (PC300LC-7E0)...834
      BRAKE VALVE OPERATION...836
        FUNCTION...836
    TRAVEL MOTOR...838
      TYPE: KMV200ADT-2...838
      OPERATION OF MOTOR...842
    PARKING BRAKE (PC300HD-7E0)...844
      BRAKE VALVE OPERATION...846
        FUNCTION...846
    SAFETY VALVE...848
      FUNCTION...848
    SWING MOTOR...851
      TYPE: KMF230ABE-5...851
        SPECIFICATIONS...851
      SWING HOLDING BRAKE...854
        OPERATION...854
        OPERATION...854
      RELIEF VALVE PORTION...855
        OUTLINE...855
        FUNCTION...855
        OPERATION...855
    REVERSE PREVENTION VALVE...856
      EXPLANATORY DRAWING OF EFFECTS...857
        FUNCTION...858
        OPERATION...858
    HYDRAULIC CYLINDERS...859
      BOOM CYLINDER...859
      ARM CYLINDER...859
      BUCKET CYLINDER...860
    WORK EQUIPMENT PIVOT POINT MEASUREMENTS...861
      BOSS BUSHING/PINS...861
      DIMENSION OF ARM...863
      DIMENSION OF BUCKET...865
    CAB AND ATTACHMENTS...867
      AIR CONDITIONER PIPING...867
    ELECTRICAL SYSTEM...868
      ENGINE CONTROL...868
        OUTLINE...868
        OPERATION OF SYSTEM...869
    ELECTRONIC COMPONENTS...870
      FUEL CONTROL DIAL...870
        FUNCTION...870
      ENGINE CONTROLLER...871
      COOLANT TEMPERATURE SENSOR...875
      OIL PRESSURE SWITCH...875
      ENGINE SPEED SENSOR...876
      BOOST PRESSURE AND TEMPERATURE SENSOR...876
      WIF (WATER-IN-FUEL DETECTION) SENSOR...877
      ENGINE OIL LEVEL SENSOR...877
    ELECTRONIC CONTROL SYSTEM...878
      CONTROL FUNCTION...878
        SYSTEM DIAGRAM...879
      ENGINE AND PUMP CONTROL FUNCTION...881
      PUMP AND VALVE CONTROL...885
        LS CONTROL FUNCTION...886
        CUT-OFF FUNCTION...886
        2-STAGE RELIEF FUNCTION...886
      POWER MAXIMIZING AND MACHINE PUSH-UP...887
      AUTO-DECELERATION...889
        OPERATION...889
      AUTO-WARM-UP AND OVERHEAT PREVENTION...890
      SWING CONTROL...892
      TRAVEL CONTROL...894
      ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR (IF EQUIPPED)...896
    SYSTEM COMPONENTS...897
      PPC OIL PRESSURE SWITCH...897
        FUNCTION...897
      OIL PRESSURE SENSOR...898
        OPERATION...898
      PUMP PRESSURE SENSOR (HIGH PRESSURE)...899
        OPERATION...899
      PUMP CONTROLLER...900
    MONITOR SYSTEM...904
      MACHINE MONITOR...905
        OUTLINE...905
    MONITOR CONTROL AND DISPLAY...908
      MONITOR...908
      DISPLAY...909
    SWITCHES...913
      BRIGHTNESS, CONTRAST ADJUSTMENT...921
      SERVICE METER CHECK FUNCTION...922
      DISPLAY LCD CHECK FUNCTION...922
      USER CODE DISPLAY FUNCTION...923
    SENSOR...925
      HYDRAULIC OIL LEVEL SENSOR...925
      HYDRAULIC OIL AND COOLANT TEMPERATURE SENSOR...925
      FUEL LEVEL SENSOR...926
      AIR CLEANER CLOGGING SENSOR...927
    KOMTRAX TERMINAL SYSTEM...928
      KOMTRAX TERMINAL...929
  20 TESTING, ADJUSTING AND TROUBLESHOOTING...932
    TESTING AND ADJUSTING...934
      STANDARD VALUE TABLES...934
        ENGINE RELATED...934
        CHASSIS RELATED...935
      SERVICE TOOLS...943
        ENGINE SERVICE TOOLS...943
        CHASSIS SERVICE TOOLS...944
      ENGINE...945
        AIR BOOST PRESSURE...945
        AIR COMPRESSOR BELT TENSION...945
        BLOW-BY PRESSURE...945
        COMPRESSION PRESSURE...945
        ENGINE OIL PRESSURE...945
        ENGINE RPM...945
        ENGINE SPEED...945
        EXHAUST GAS COLOR...945
        FUEL INJECTION TIMING...945
        VALVE CLEARANCE...945
      MEASURING ENGINE FUNCTIONS...946
        MEASURE ENGINE SPEED WITH MACHINE MONITOR...946
          PREPARATION...946
          MEASURING LOW IDLE SPEED...946
          MEASURING HIGH IDLE SPEED...946
          MEASURING THE ENGINE SPEED WHEN 2-PUMPS ARE RELIEVED...946
          MEASURING THE ENGINE SPEED AT 2-PUMP RELIEF AND POWER MAXIMIZING (NEAR RATED SPEED)...946
          MEASURING THE SPEED WHEN AUTO-DECELERATION SPEED IS IN OPERATION...946
        CYLINDER CUT-OUT OPERATION...947
        NO INJECTION CRANKING OPERATION...947
      CHECK AND ADJUST REFRIGERANT COMPRESSOR BELT...948
        INSPECTION...948
        ADJUSTMENT...948
      MEASURING SWING CIRCLE BEARING CLEARANCE...949
      CHECK AND ADJUST TRACK SHOE TENSION...950
        INSPECTION...950
        ADJUSTMENt...950
      CHECK AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT...951
        MEASURING...951
        ADJUSTING...953
      CHECKING CONTROL CIRCUIT OIL PRESSURE...956
        MEASURING...956
      CHECK AND ADJUST PUMP PC CONTROL CIRCUIT OIL PRESSURE...957
        MEASURING...957
        ADJUSTING...959
      CHECK AND ADJUST PUMP LS CONTROL CIRCUIT OIL PRESSURE...960
        MEASURING...960
        ADJUSTING...964
      MEASURING SOLENOID VALVE OUTPUT PRESSURE...965
      MEASURING PPC VALVE OUTPUT PRESSURE...969
      ADJUSTING PLAY IN WORK EQUIPMENT AND SWING PPC VALVES...970
      TROUBLESHOOTING HYDRAULIC DRIFT IN WORK EQUIPMENT...971
        INSPECTION OF BOOM AND BUCKET CYLINDERS...971
        INSPECTION OF ARM CYLINDER...971
        INSPECTION OF BOOM LOCK VALVE...972
        INSPECTION OF PPC VALVE...972
      RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...973
        MEASURING OIL LEAKAGE AMOUNT...973
      BLEEDING AIR FROM VARIOUS SYSTEMS...976
      DIODE INSPECTION PROCEDURES...978
      SPECIAL FUNCTIONS OF MACHINE MONITOR...979
        ORDINARY AND SPECIAL FUNCTIONS OF MACHINE MONITOR...980
        OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE)...981
      SERVICE MENU OPERATION AND DISPLAY...989
        SWITCHING TO SERVICE MENU...989
        MONITORING [01] FUNCTION...990
        FUNCTION OF ABNORMALITY RECORD [02]...995
        FUNCTION OF MAINTENANCE RECORD [03]...997
        FUNCTION OF MAINTENANCE MODE CHANGE [04]...998
        FUNCTION OF PHONE NUMBER ENTRY [05]...999
        FUNCTION OF DEFAULT [06]...1000
        FUNCTION OF ADJUSTMENT [07]...1002
        FUNCTION OF CYLINDER CUT OUT OPERATION [08]...1003
        FUNCTION OF NO INJECTION CRANKING [09]...1006
      HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...1008
      PROCEDURE FOR TURNING ON KOMTRAX TERMINAL...1009
      KOMTRAX TERMINAL LAMP INDICATIONS...1012
      TROUBLESHOOTING ELECTRICAL SYSTEM...1015
      PM-CLINIC INSPECTION TABLE...1018
    TROUBLESHOOTING (GENERAL)...1024
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...1025
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...1027
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...1028
        PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT...1028
        HANDLING ELECTRONIC CONTROL UNIT...1033
        POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS...1034
        POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...1035
      CHECKS BEFORE TROUBLESHOOTING...1037
        CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS...1038
        TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS...1039
        TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS...1041
      POSSIBLE PROBLEMS WHEN TROUBLESHOOTING A MODE...1043
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...1046
      T-ADAPTER TABLE...1068
    TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...1072
      CONNECTOR TYPES AND LOCATIONS...1077
      CONNECTOR LAYOUT DRAWINGS...1083
      TROUBLESHOOTING BY FAILURE CODE...1089
        BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED...1092
        LOCATION OF FUSE BOX AND FUSE NUMBERS...1093
      INFORMATION CONTAINED IN TESTING PROCEDURES...1095
      FAILURE CODE [A000N1]...1097
        ENGINE OVER SPEED...1097
      FAILURE CODE [AA10NX]...1098
        AIR CLEANER CLOG SENSOR SYSTEM...1098
      FAILURE CODE [AB00KE]...1100
        CHARGE VOLTAGE IS LOW...1100
      FAILURE CODE [B@BAZG]...1102
        ENGINE OIL PRESSURE DROP...1102
      FAILURE CODE [B@BAZK]...1104
        ENGINE OIL LEVEL DROP...1104
      FAILURE CODE [B@BCNS]...1106
        COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)...1106
      FAILURE CODE [B@BCZK]...1108
        ENGINE COOLANT LEVEL DROP...1108
      FAILURE CODE [B@HANS]...1110
        HYDRAULIC OIL OVERHEAT CONDITION...1110
      FAILURE CODE [CA111]...1112
        CRITICAL INTERNAL FAILURE...1112
      FAILURE CODE [CA115]...1113
        ENGINE NE AND BACKUP SPEED SENSOR ERROR...1113
      FAILURE CODE [CA122]...1114
        CHARGE AIR PRESSURE SENSOR HIGH ERROR...1114
      FAILURE CODE [CA123]...1116
        CHARGE AIR PRESSURE SENSOR LOW ERROR...1116
      FAILURE CODE [CA131]...1118
        THROTTLE SENSOR HIGH ERROR...1118
      FAILURE CODE [CA132]...1120
        THROTTLE SENSOR LOW ERROR...1120
      FAILURE CODE [CA144]...1122
        COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)...1122
      FAILURE CODE [CA145]...1124
        COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (KX)...1124
      FAILURE CODE [CA153]...1126
        CHARGE AIR PRESSURE SENSOR HIGH ERROR...1126
      FAILURE CODE [CA154]...1128
        CHARGE AIR PRESSURE SENSOR LOW ERROR...1128
      FAILURE CODE [CA187]...1130
        SENSOR SUPPLY 2 VOLT LOW ERROR...1130
      FAILURE CODE [CA221]...1132
        AMBIENT PRESSURE SENSOR HIGH ERROR...1132
      FAILURE CODE [CA222]...1134
        AMBIENT PRESSURE SENSOR LOW ERROR...1134
      FAILURE CODE [CA227]...1136
        SENSOR SUPPLY 2 VOLT HIGH ERROR...1136
      FAILURE CODE [CA234]...1138
        ENGINE OVER SPEED...1138
      FAILURE CODE [CA238]...1139
        SPEED SENSOR SUPPLY VOLT ERROR...1139
      FAILURE CODE [CA271]...1140
        UMV/PCV1 SHORT ERROR...1140
      FAILURE CODE [CA272]...1142
        UMV/PCV1 OPEN ERROR...1142
      FAILURE CODE [CA322]...1143
        OPEN IN NO. 1 INJECTOR SOLENOID VALVE...1143
      FAILURE CODE [CA323]...1145
        OPEN IN NO. 5 INJECTOR SOLENOID VALVE...1145
      FAILURE CODE [CA324]...1147
        OPEN IN NO. 3 INJECTOR SOLENOID VALVE...1147
      FAILURE CODE [CA325]...1149
        OPEN IN NO. 6 INJECTOR SOLENOID VALVE...1149
      FAILURE CODE [CA331]...1151
        OPEN IN NO. 2 INJECTOR SOLENOID VALVE...1151
      FAILURE CODE [CA332]...1153
        OPEN IN NO. 4 INJECTOR SOLENOID VALVE...1153
      FAILURE CODE [CA342]...1155
        CALIBRATION CODE INCOMPATIBILITY...1155
      FAILURE CODE [CA351]...1156
        INJECTOR DRIVE CIRCUIT ERROR...1156
      FAILURE CODE [CA352]...1158
        AMBIENT PRESSURE SENSOR 1 VOLT LOW ERROR...1158
      FAILURE CODE [CA386]...1160
        AMBIENT PRESSURE SENSOR 1 VOLT HIGH ERROR...1160
      FAILURE CODE [CA428]...1162
        WATER IN FUEL SENSOR HIGH ERROR...1162
      FAILURE CODE [CA429]...1164
        WATER IN FUEL SENSOR LOW ERROR...1164
      FAILURE CODE [CA441]...1166
        BATTERY VOLTAGE LOW ERROR...1166
      FAILURE CODE [CA442]...1168
        BATTERY VOLTAGE HIGH ERROR...1168
      FAILURE CODE [CA449]...1170
        RAIL PRESSURE VERY HIGH...1170
      FAILURE CODE [CA451]...1173
        RAIL PRESSURE SENSOR HIGH ERROR...1173
      FAILURE CODE [CA452]...1175
        RAIL PRESSURE SENSOR LOW ERROR...1175
      FAILURE CODE [CA553]...1177
        RAIL PRESSURE ERROR...1177
      FAILURE CODE [CA559]...1178
        RAIL PRESSURE VERY LOW...1178
      FAILURE CODE [CA689]...1180
        ENGINE NE SPEED SENSOR ERROR...1180
      FAILURE CODE [CA731]...1182
        ENGINE BACK-UP SPEED SENSOR PHASE ERROR...1182
      FAILURE CODE [CA757]...1183
        PERSISTENT DATA LOSS ERROR...1183
      FAILURE CODE [CA778]...1185
        ENGINE BKUP SPEED SENSOR ERROR...1185
      FAILURE CODE [CA1633]...1187
        (KOMNET) DATALINK HAS TIME-OUT ERROR...1187
      FAILURE CODE [CA2185]...1189
        THROTTLE SENSOR HIGH ERROR...1189
      FAILURE CODE [CA2186]...1191
        THROTTLE SENSOR LOW ERROR...1191
      FAILURE CODE [CA2249]...1193
        RAIL PRESSURE VERY LOW...1193
      FAILURE CODE [CA2265]...1195
        ELECTRIC LIFT PUMP HIGH ERROR...1195
      FAILURE CODE [CA2266]...1196
        ELECTRIC LIFT PUMP LOW ERROR...1196
      FAILURE CODE [CA2556]...1197
        GRID HEATER RELAY VOLT LOW ERROR...1197
      FAILURE CODE [CA2555]...1199
        GRID HEATER RELAY VOLT HIGH ERROR...1199
      FAILURE CODE [D110KB]...1201
        BATTERY RELAY DRIVE S/C...1201
      FAILURE CODE [D196KA]...1203
        SERVICE RETURN RELAY ERROR...1203
      FAILURE CODE [D196KB]...1205
        SERVICE RETURN RELAY ERROR...1205
      FAILURE CODE [DA25KP]...1207
        SENSOR POWER ERROR...1207
      FAILURE CODE [DA2RMC]...1209
        PUMP COMMUNICATION ERROR...1209
      FAILURE CODE [DA2SKQ]...1211
        MODEL SELECTION ERROR...1211
      FAILURE CODE [DAFRMC]...1213
        MONITOR COMMUNICATION ERROR...1213
      FAILURE CODE [DHPAMA]...1215
        F PUMP PRESSURE SENSOR ERROR...1215
      FAILURE CODE [DHPBMA]...1217
        R PUMP PRESSURE SENSOR ERROR...1217
      FAILURE CODE [DHS3MA]...1219
        ARM CURL PRESSURE SENSOR ERROR...1219
      FAILURE CODE [DHS4MA]...1221
        CURL PPC PRESSURE SENSOR ERROR...1221
      FAILURE CODE [DW43KA]...1223
        TRAVEL SPEED SOLENOID ERROR...1223
      FAILURE CODE [DW43KB]...1225
        TRAVEL SPEED SOLENOID ERROR...1225
      FAILURE CODE [DW45KA]...1227
        SWING BRAKE SOLENOID ERROR...1227
      FAILURE CODE [DW45KB]...1230
        SWING BRAKE SOLENOID ERROR...1230
      FAILURE CODE [DW91KA]...1233
        TRAVEL JUNCTION SOLENOID ERROR...1233
      FAILURE CODE [DW91KB]...1235
        TRAVEL JUNCTION SOLENOID ERROR...1235
      FAILURE CODE [DWJ0KA]...1237
        MERGE-DIVIDER SOLENOID ERROR...1237
      FAILURE CODE [DWJ0KB]...1239
        MERGE-DIVIDER SOLENOID ERROR...1239
      FAILURE CODE [DWK0KA]...1241
        2-STAGE RELIEF SOLENOID ERROR...1241
      FAILURE CODE [DWK0KB]...1243
        2-STAGE RELIEF SOLENOID ERROR...1243
      FAILURE CODE [DXA0KA]...1245
        PC-EPC SOLENOID ERROR...1245
      FAILURE CODE [DXA0KB]...1247
        PC-EPC SOLENOID ERROR...1247
      FAILURE CODE [DXE0KA]...1249
        LS-EPC SOLENOID ERROR...1249
      FAILURE CODE [DXE0KB]...1251
        LS-EPC SOLENOID ERROR...1251
      FAILURE CODE [DXE4KA]...1253
        SERVICE CURRENT EPC ERROR...1253
      FAILURE CODE [DXE4KB]...1255
        SERVICE CURRENT EPC ERROR...1255
      FAILURE CODE [DY20KA]...1257
        WINDSHIELD WIPER MOTOR DRIVE ERROR...1257
      FAILURE CODE [DY20MA]...1259
        WINDSHIELD WIPER MOTOR DRIVE ERROR...1259
      FAILURE CODE [DY2CKB]...1261
        WINDSHIELD WASHER DRIVE ERROR...1261
      FAILURE CODE [DY2DKB]...1263
        WINDSHIELD WIPER DRIVE ERROR...1263
      FAILURE CODE [DY2EKB]...1265
        WINDSHIELD WIPER DRIVE ERROR...1265
      [E-1]...1267
        ENGINE WILL NOT CRANK...1267
      [E-2]...1269
        AUTO DECELERATOR DOES NOT WORK...1269
      [E-3]...1270
        AUTO ENGINE WARM UP DEVICE DOES NOT WORK...1270
      [E-4]...1271
        COLD START PRE-HEATER DOES NOT WORK...1271
      [E-5]...1273
        ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE...1273
      [E-6]...1275
        POWER MAXIMIZING FUNCTION DOES NOT OPERATE...1275
      [E-7]...1277
        MACHINE MONITOR DOES NOT OPERATE...1277
      [E-8]...1279
        MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS...1279
      [E-9]...1280
        MACHINE MONITOR DOES NOT DISPLAY ITEMS CORRECTLY...1280
      [E-10]...1281
        MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING...1281
      [E-11]...1282
        COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT...1282
      [E-12]...1284
        HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY...1284
      [E-13]...1286
        MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING...1286
      [E-17]...1287
        SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY...1287
      [E-15]...1289
        WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS...1289
      [E-16]...1291
        WINDSHIELD WIPER AND WASHER DO NOT OPERATE...1291
        WINDSHIELD WASHER DRIVE ERROR...1293
      [E-17]...1295
        MACHINE PUSH-UP FUNCTION DOES NOT OPERATE...1295
      [E-18]...1297
        BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR...1297
      [E-19]...1299
        BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR...1299
      [E-20]...1301
        ARM IN NOT CORRECTLY DISPLAYED ON MONITOR...1301
      [E-21]...1303
        ARM OUT NOT CORRECTLY DISPLAYED ON MONITOR...1303
      [E-22]...1305
        BUCKET CURL CORRECTLY DISPLAYED ON MONITOR...1305
      [E-23]...1307
        BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR...1307
      [E-24]...1309
        SWING NOT CORRECTLY DISPLAYED ON MONITOR...1309
      [E-25]...1311
        TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR...1311
      [E-26]...1313
        TRAVEL DIFFERENTIAL NOT CORRECTLY DISPLAYED ON MONITOR...1313
      [E-27]...1315
        SERVICE NOT CORRECTLY DISPLAYED ON MONITOR...1315
      [E-28]...1317
        KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...1317
      [E-29]...1319
        AIR CONDITIONER SYSTEM DOES NOT WORK...1319
      [E-30]...1321
        TRAVEL ALARM DOES NOT SOUND...1321
      [E-31]...1323
        HORN DOES NOT SOUND...1323
    TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...1328
      SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SY...1330
      INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...1332
      [H-1]...1333
        WORK EQUIPMENT, TRAVEL AND SWING SPEEDS ARE SLOW...1333
      [H-2]...1334
        ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS...1334
      [H-3]...1335
        NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT...1335
      [H-4]...1335
        ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP...1335
      [H-5]...1336
        AUTO-DECELERATOR DOES NOT WORK...1336
      [H-6]...1336
        FINE CONTROL MODE DOES NOT FUNCTION...1336
      [H-7]...1337
        BOOM MOVES SLOWLY OR LACKS POWER...1337
      [H-8]...1338
        WORK EQUIPMENT MOVES SLOWLY OR LACKS POWER...1338
      [H-9]...1339
        BUCKET MOVES SLOWLY OR LACKS POWER...1339
      [H-10]...1339
        WORK EQUIPMENT DOES NOT MOVE IN A INDEPENDENT OPERATION...1339
      [H-11]...1340
        WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT...1340
      [H-12]...1341
        WORK EQUIPMENT HAS EXCESSIVE LAG TIM...1341
      [H-13]...1341
        OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT...1341
      [H-14]...1342
        ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE...1342
      [H-15]...1342
        IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY...1342
      [H-16]...1342
        IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY...1342
      [H-17]...1343
        IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY...1343
      [H-18]...1344
        MACHINE SWERVES WHEN TRAVELING...1344
      [H-19]...1345
        MACHINE TRAVELS SLOWLY...1345
      [H-20]...1346
        MACHINE CANNOT BE STEERED EASILY OR LACKS POWER...1346
      [H-21]...1347
        TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING...1347
      [H-22]...1347
        TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY)...1347
      [H-23]...1348
        MACHINE DOES NOT SWING...1348
      [H-24]...1349
        SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW...1349
      [H-25]...1350
        EXCESSIVE OVERRUN WHEN STOPPING SWING...1350
      [H-26]...1351
        THERE IS A SUDDEN SHOCK WHEN STOPPING SWING...1351
      [H-27]...1351
        ABNORMAL NOISE CAUSED WHEN STOPPING SWING...1351
  30 DISASSEMBLY AND ASSEMBLY...1353
    METHOD OF USING MANUAL...1357
    COATING MATERIALS LIST...1358
    SPECIAL TOOLS LIST...1362
    SKETCHES OF SPECIAL TOOLS...1366
    PRECAUTIONS DURING OPERATION...1368
      PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...1368
      PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...1369
      PRECAUTIONS WHEN COMPLETING THE OPERATIONS...1370
      OTHER PRECAUTIONS...1370
    ENGINE...1371
    CONNECTOR REPAIR PROCEDURES...1372
      CONTACT TERMINAL REMOVAL (HD30 TYPE)...1372
      STRIPPING INSULATION...1373
      CRIMPING CONTACT TERMINAL (HD30 TYPE)...1374
      INSERTION OF CONTACT TERMINAL (HD30 TYPE)...1375
      CONTACT TERMINAL REMOVAL (DT TYPE)...1376
      STRIPPING INSULATION...1377
      CRIMPING CONTACT TERMINAL (DT TYPE)...1378
      INSERTION OF CONTACT TERMINAL (DT TYPE)...1379
    ENGINE AND COOLING SYSTEM...1380
      REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY...1380
        SPECIAL TOOLS...1380
        REMOVAL...1380
        INSTALLATION...1382
      REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...1385
        SPECIAL TOOLS...1385
        REMOVAL...1385
        INSTALLATION...1387
      REMOVAL AND INSTALLATION OF ENGINE REAR SEAL...1389
        SPECIAL TOOLS...1389
        REMOVAL...1389
        INSTALLATION...1391
      REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...1396
        SPECIAL TOOLS...1396
        REMOVAL...1396
        INSTALLATION...1403
      REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...1411
        REMOVAL...1411
        INSTALLATION...1412
      REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...1413
        REMOVAL...1413
        INSTALLATION...1415
      REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY...1416
        REMOVAL...1416
        INSTALLATION...1416
      REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY...1417
        SPECIAL TOOLS...1417
        REMOVAL...1417
        INSTALLATION...1422
    POWER TRAIN...1423
      REMOVAL AND INSTALLATION OF FINALDRIVE ASSEMBLY...1423
        REMOVAL...1423
        INSTALLATION...1424
      DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE...1425
        SPECIAL TOOLS...1425
        DISASSEMBLY...1425
        ASSEMBLY...1430
      REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...1436
        REMOVAL...1436
        INSTALLATION...1437
      DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...1438
        SPECIAL TOOLS...1438
        DISASSEMBLY...1438
        ASSEMBLY...1441
      REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY...1448
        REMOVAL...1448
        INSTALLATION...1448
    UNDERCARRIAGE AND FRAME...1449
      DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY...1449
        SPECIAL TOOLS...1449
        ASSEMBLY...1449
      DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...1451
        SPECIAL TOOLS...1451
        ASSEMBLY...1451
      DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY...1453
        SPECIAL TOOLS...1453
        DISASSEMBLY...1453
        ASSEMBLY...1454
      DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY...1457
        SPECIAL TOOLS...1457
        DISASSEMBLY...1457
        ASSEMBLY...1459
      REMOVAL AND INSTALLATION OF SPROCKET...1461
        REMOVAL...1461
        INSTALLATION...1461
      EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY...1462
        SPECIAL TOOLS...1462
        EXPANSION OF TRACK SHOE...1462
        INSTALLATION OF TRACK SHOE...1463
      REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY...1465
        REMOVAL...1465
        INSTALLATION...1467
      REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY...1468
        REMOVAL...1468
        INSTALLATION...1468
    HYDRAULIC SYSTEM...1469
      REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY...1469
        REMOVAL...1469
        INSTALLATION...1470
      DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY...1471
        SPECIAL TOOLS...1471
        DISASSEMBLY...1471
        ASSEMBLY...1472
      REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY...1473
        REMOVAL...1473
        INSTALLATION...1475
      REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY...1476
        REMOVAL...1476
        INSTALLATION...1479
      DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY...1480
        SPECIAL TOOLS...1480
      REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY...1483
        SPECIAL TOOLS...1483
        REMOVAL...1483
        INSTALLATION...1486
      REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT...1487
        REMOVAL...1487
        INSTALLATION...1487
      DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY...1488
        DISASSEMBLY...1488
        ASSEMBLY...1488
      DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...1490
        DISASSEMBLY...1490
        ASSEMBLY...1490
      DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...1491
        SPECIAL TOOLS...1491
        DISASSEMBLY...1491
        ASSEMBLY...1494
    WORK EQUIPMENT...1498
      REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...1498
        SPECIAL TOOLS...1498
        REMOVAL...1498
        INSTALLATION...1500
    CAB AND ITS ATTACHMENTS...1502
      REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...1502
        REMOVAL...1502
        INSTALLATION...1504
      REMOVAL AND INSTALLATION OF OPERATOR’S CAB FIXED WINDOW...1505
        SPECIAL TOOLS...1506
        REMOVAL...1506
        INSTALLATION...1507
      REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY...1518
        REMOVAL...1518
        INSTALLATION...1521
    ELECTRICAL SYSTEM...1526
      REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...1526
        SPECIAL TOOLS...1526
        REMOVAL...1526
        INSTALLATION...1529
      REMOVAL AND INSTALLATION OFMACHINE MONITOR...1530
        REMOVAL...1530
        INSTALLATION...1530
      REMOVAL AND INSTALLATION OF PUMP CONTROLLER...1531
        REMOVAL...1531
        INSTALLATION...1531
      REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL...1532
        REMOVAL...1532
        INSTALLATION...1532
      REMOVAL AND INSTALLATION OF ENGINE CONTROLLER...1533
        REMOVAL...1533
        INSTALLATION...1533
  90 OTHERS...1535
    HYDRAULIC CIRCUIT DIAGRAMS...1537
      (VIEW “A”) 1 OF 5...1537
      (VIEW “A”) 2 OF 5...1539
      (VIEW “A”) 3 OF 5...1541
      (VIEW “A”) 4 OF 5...1543
      (VIEW “A”) 5 OF 5...1545
      (VIEW “B”) 1 OF 6...1547
      (VIEW “B”) 2 OF 6...1549
      (VIEW “B”) 3 OF 6...1551
      (VIEW “B”) 4 OF 6...1553
      (VIEW “B”) 5 OF 6...1555
      (VIEW “B”) 6 OF 6...1557
    ELECTRICAL CIRCUIT DIAGRAMS...1559
      TO CABIN HARNESS...1559
      CABIN HARNESS VIEW 1...1561
      CABIN HARNESS VIEW 2...1563
      CONTROLLER (CR700) VIEW...1565
      FLOOR HARNESS VIEW...1567
      MONITOR AND RADIO HARNESS VIEW...1569
      LEFT CONSOLE, FUSE PANEL AND KOMTRAX CONTROLLER...1571
      WARNING AND INDICATOR LAMPS...1573
      ENGINE AND DRIVE SYSTEM SENSORS AND CONTROLLERS...1575
      ENGINE SENSORS AND CONTROLLERS (PC300LC-7E0)...1577
      FUEL INJECTOR SYSTEM VIEW (PC300LC-7E0)...1579
      ENGINE SENSORS AND CONTROLLERS (PC300HD-7E0)...1581
      FUEL INJECTOR SYSTEM VIEW (PC300HD-7E0)...1583

Komatsu Logging/Road Builder Excavator Excavator GALEO PC300LC-7E0, PC300HD-7E0, PC300LL-7E0 Repair Service Manuals