Komatsu Hydraulic Excavator PC300LC-7L, PC300HD-7L, PC300LL-7L Repair Service Manuals
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Model:
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, and 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.
CEBM009104 - Hydraulic Excavator PC300LC-7L, PC300HD-7L Shop Manual.pdf
CEBM012100 - Hydraulic Excavator GALEO PC300LL-7L Shop Manual.pdf
CEAM3006C1 - Hydraulic Excavator PC300LC-6, PC300HD-6 Operation & Maintenance Manual.pdf
CEAM003300 - Hydraulic Excavator PC300LC-6, PC300HD-6 Operation & Maintenance Manual.pdf
CEAM005902 - Hydraulic Excavator PC300LC-6, PC300HD-6 Operation & Maintenance Manual.pdf
CEAM008802 - Hydraulic Excavator GALEO PC300LC-7L, PC300HD-7L Operation & Maintenance Manual.pdf
CEAM012300 - Logging Excavator GALEO PC300LL-7L Operation & Maintenance Manual.pdf
CEAM207074 - Hydraulic Excavator PC300-5 (Mighty), PC300LC-5 (Mighty), PC300LC-5K, PC300HD-5 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,211 pages
File Format: PDF
Language: English
CEAM003300 - Hydraulic Excavator PC300LC-6, PC300HD-6 Operation & Maintenance Manual....2
INTRODUCTION ....5
1. FORWARD ....6
2. SAFETY INFORMATION ....7
3. INTRODUCTION ....8
3.1 INTENDED USE ....8
3.2 FEATURES ....8
3.3 BREAKING IN THE MACHINE ....8
4. PLATE LOCATIONS AND TABLE TO ENTER P.I.N. AND DISTRIBUTOR ....9
4.1 P.I.N. PLATE LOCATION ....9
4.2 ENGINE SERIAL NUMBER PLATE ....9
4.3 TABLE TO ENTER NUMBERS AND DISTRIBUTOR ....9
5. TABLE OF CONTENTS ....10
SAFETY....14
6. GENERAL PRECAUTIONS....15
7. PRECAUTIONS DURING OPERATION....23
7.1 BEFORE STARTING ENGINE ....23
7.2 OPERATING MACHINE ....25
7.3 TRANSPORTATION ....31
7.4 BATTERY....33
7.5 TOWING ....35
7.6 BUCKET WITH HOOK ....36
8. PRECAUTIONS FOR MAINTENANCE....37
8.1 BEFORE CARRYING OUT MAINTENANCE ....37
8.2 DURING MAINTENANCE ....41
9. POSITION FOR ATTACHING SAFETY LABELS....47
OPERATION....51
10. GENERAL VIEW....52
10.1 GENERAL VIEW OF MACHINE ....52
10.2 GENERAL VIEW OF OPERATORS COMPARTMENT ....53
10.3 GENERAL VIEW OF MONITOR PANEL ....54
11. EXPLANATION OF COMPONENTS....55
11.1 MACHINE MONITOR....55
11.2 SWITCHES....65
11.3 CONTROL LEVERS AND PEDALS....69
11.4 SEAT BELT....73
11.5 ROOF VENT....74
11.6 FRONT WINDOW....75
11.7 DOOR LOCK....78
11.8 CAP, COVER WITH LOCK....78
11.9 HOT AND COOL BOX....79
11.10 STORAGE BOX....79
11.11 ASHTRAY....79
11.12 AIR CONDITIONER....80
11.13 CAB HEATER....83
11.14 PREPARATION FOR CAB HEATER....84
11.15 AM/FM RADIO....85
11.16 ELECTRIC POWER TAKE OUT ADAPTER....89
11.17 FUSE....90
11.18 FUSIBLE LINK....91
11.19 CONTROLLERS....91
11.20 TOOL BOX....91
11.21 GREASE GUN HOLDER....91
11.22 HANDLING ACCUMULATOR....92
12. OPERATION....93
12.1 CHECK BEFORE STARTING ENGINE....93
12.2 STARTING ENGINE....104
12.3 OPERATIONS AND CHECKS AFTER ENGINE STARTS....107
12.4 MOVING MACHINE....113
12.5 STEERING MACHINE....117
12.6 STOPPING MACHINE....119
12.7 SWINGING....120
12.8 OPERAION OF WORK EQUIPMENT ....121
12.9 HANDLING ACTIVE MODE ....122
12.10 HANDLING WORKING MODE ....122
12.11 PROHIBITED OPERATIONS ....124
12.12 PRECAUTIONS FOR OPERATION ....126
12.13 PRECAUTIONS WHEN TRAVELING ON HILLS ....127
12.14 HOW TO ESCAPE FROM MUD ....129
12.15 WORK POSSIBLE WITH HYDRAULIC EXCAVATOR ....129
12.16 REPLACE OR INVERT BUCKET ....131
12.17 PARKING MACHINE ....133
12.18 CHECK AFTER FINISHING WORK ....134
12.19 STOPPING ENGINE....135
12.20 CHECK AFTER STOPPING ENGINE....135
12.21 LOCKING ....136
13. TRANSPORTATION....137
13.1 TRANSPORTATION PROCEDURE ....137
13.2 LOADING, UNLOADING OF TRAILERS ....137
13.3 TRACK FRAME GAUGE - PC300HD-6 ....143
13.4 PRECAUTIONS FOR TRANSPORTATION ....144
14. COLD WEATHER OPERATION....145
14.1 PRECAUTIONS FOR LOW TEMPERATURE ....145
14.2 PRECAUTIONS AFTER WORK COMPLETION ....147
14.3 AFTER COLD WEATHER ....147
15. LONG TERM STORAGE....148
15.1 BEFORE STORAGE ....148
15.2 DURING STORAGE ....148
15.3 AFTER STORAGE ....149
15.4 STARTING MACHINE AFTER LONG TERM STORAGE ....149
16. TROUBLESHOOTING....150
16.1 PHENOMENA THAT ARE NOT FAILURES ....150
16.2 METHOD OF TOWING MACHINE ....150
16.3 METHOD FOR LIGHT WEIGHT TOWING ....150
16.4 PRECAUTION ON PARTICULAR JOB SITES ....150
16.5 IF BATTERY IS DISCHARGED ....151
16.6 OTHER TROUBLE ....154
MAINTENANCE....158
17. GUIDES TO MAINTENANCE....159
18. OUTLINES OF SERVICE....161
18.1 OUTLINE OF OIL, FUEL, COOLANT ....161
18.2 OUTLINE OF ELECTRICAL SYSTEM ....163
18.3 OUTLINE OF HYDRAULIC SYSTEM ....163
18.4 OUTLINE OF FUEL SYSTEM ....164
19. WEAR PARTS LIST....165
20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....166
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ....166
20.2 ENGINE OIL SPECIFICATIONS ....167
20.3 DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYDRAULIC SYSTEM OIL SPECIFICA- TIONS ....168
20.4 FINAL DRIVE OIL SPECIFICATIONS ....168
20.5 DIESEL FUEL SPECIFICATIONS ....168
20.6 COOLANT SPECIFICATIONS ....169
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....175
21.1 INTRODUCTION OF NECESSARY TOOLS ....175
21.2 TORQUE LIST ....176
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....177
23. MAINTENANCE SCHEDULE CHART....178
23.1 SCHEDULED MAINTENANCE CHART ....178
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER ....180
24. SERVICE PROCEDURE....181
24.1 INITIAL 250 HOURS SERVICE ....181
24.2 WHEN REQUIRED ....182
24.3 CHECK BEFORE STARTING ....202
24.4 EVERY 50 HOURS SERVICE ....206
24.5 EVERY 100 HOURS SERVICE ....208
24.6 EVERY 250 HOURS SERVICE ....211
24.7 EVERY 500 HOURS SERVICE ....215
24.8 EVERY 1000 HOURS SERVICE ....223
24.9 EVERY 2000 HOURS SERVICE ....226
24.10 EVERY 4000 HOURS SERVICE ....232
24.11 EVERY 5000 HOURS SERVICE ....233
SPECIFICATIONS....237
25. MACHINE SPECIFICATIONS....238
25.1 GENERAL ....238
25.2 MACHINE SPECIFICATIONS ....239
25.3 WORKING RANGE ....241
25.4 LIFTING CAPACITY ....243
OPTIONS, ATTACHMENTS....250
26. GENERAL PRECAUTIONS....251
26.1 PRECAUTIONS RELATED TO SAFETY ....251
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS ....252
27. BUCKET WITH HOOK....253
27.1 CHECKING FOR DAMAGE ....253
27.2 PROHIBITED OPERATIONS ....253
27.3 PRECAUTIONS DURING OPERATIONS ....253
28. MACHINES READY FOR ATTACHMENT....254
28.1 GENERAL LOCATIONS ....254
28.2 HYDRAULIC CIRCUIT ....256
28.3 PROCEDURE FOR REMOVAL AND INSTALLATION OF ATTACHMENT ....258
28.4 OPERATION ....259
28.5 LONG-TERM STORAGE ....260
28.6 SPECIFICATIONS ....260
29. INTRODUCTION OF ATTACHMENTS....261
29.1 ATTACHMENT INSTALLATION COMBINATION TABLE ....261
29.2 BUCKET SELECTION ....263
29.3 SELECTION OF TRACK SHOES ....264
29.4 HANDLING TRAPEZOIDAL BUCKET ....265
30. EXTENDING MACHINE SERVICE LIFE....266
30.1 HYDRAULIC BREAKER ....266
30.2 POWER RIPPER ....269
30.3 GRAB FORK ....271
30.4 GRAPPLE BUCKET ....272
30.5 SCRAP GRAPPLE ....273
30.6 CRUSHER AND CUTTER ....274
30.7 HYDRAULIC PILE DRIVER ....275
30.8 MULTIPURPOSE CRANE ....276
CEAM005902 - Hydraulic Excavator PC300LC-6, PC300HD-6 Operation & Maintenance Manual....279
COVER....279
INTRODUCTION....281
FOREWORD....282
SAFETY INFORMATION....283
INTRODUCTION....285
Directions Of Machine....285
Breaking-in The New Machine....285
Product Information....286
Product Identification Number (Pin)/machine Serial No. Plate....286
EPA Regulations, Engine Number Plate....286
Service Meter Location....287
Your Machine Serial Numbers And Distributor....287
SAFETY....297
SAFETY AND WARNING DECALS....298
Location Of The Safety Decals....298
Safety Labels....299
Optional Systems Decal....306
Optional Decal Locations....308
SAFETY INFORMATION....309
Safety Rules....309
If Problems Are Found....309
Working Wear And Personal Protective Items....309
Fire Extinguisher And First Aid Kit....309
Safety Equipment....310
Keep Machine Clean....310
Keep Operator's Compartment Clean....310
Fire Prevention And Explosion Prevention....310
Action If Fire Occurs....311
Handrails And Steps....312
Precautions When Working In High Places....312
Mounting And Dismounting....312
No Persons On Attachments....313
Precautions When Standing Up From Operator's Seat....313
Leaving Operator's Seat With Lock....313
Emergency Exit From Operator's Cab....313
Do Not Get Caught In Articulated Portion....314
Precautions Related To Protective Structures....314
Protection Against Falling, Flying, Intruding Objects....314
Unauthorized Modification....315
Precautions Related To Attachments And Options....315
Precautions Related To Cab Glass....315
Precautions When Running Engine Inside Building....316
Safety At Jobsite....316
Working On Loose Ground....316
Distance To High Voltage Cables....317
Ensure Good Visibility....317
Signalman's Signal And Signs....318
Asbestos Dust Hazard Prevention....318
Ventilation For Enclosed Area....318
SAFETY MACHINE OPERATION....319
Starting Engine....319
Checks Before Starting Engine....319
Safety Rules For Starting Engine....320
Starting Engine In Cold Weather....320
Starting With Booster Cables....320
OPERATION....321
Checks Before Operation....321
Safety Rules For Changing Machine Directions....321
Safety Rules For Traveling....322
Traveling On Slopes....323
Operations On Slopes....324
Prohibited Operations....324
Operations On Snow Or Frozen Surfaces....326
Parking Machine....327
TRANSPORTATION....328
Loading And Unloading....328
Shipping The Machine....329
TOWING....329
Safety Rules For Towing....329
LIFTING OBJECTS WITH BUCKET....330
Safety Rules For Lifting Objects....330
SAFETY MAINTENANCE INFORMATION....331
Warning Tag....331
Keep Work Place Clean And Tidy....331
Select Suitable Place For Inspection And Maintenance....331
Only Authorized Personnel....331
Appoint Leader When Working With Others....331
Stop Engine Before Carrying Out Maintenance....332
Two Workers For Maintenance When Engine Is Running....333
Attachments....333
Precautions When Working At High Places....333
Work Under The Machine....334
Proper Tools....334
Battery....335
Battery Hazard Prevention....335
Starting Engine With Booster Cables....336
When Using Hammer....336
Burn Prevention....337
Hot Coolant....337
Hot Oil....337
Safety Rules For High-pressure Oil....337
Precaution For High Fuel Pressure....338
Safety Handling High-pressure Hoses....338
Precaution For High Voltage....338
Noise....338
Safety First When Using High-pressure Grease To Adjust Track Tension....339
Do Not Disassemble Recoil Springs....339
Accumulator, Gas Spring....340
Compressed Air....340
Air Conditioner Maintenance....340
Personnel....340
Welding Works....340
Removing Battery Terminals....340
Waste Materials....341
Windshield Washer Fluid....341
Periodic Replacement Of Safety Critical Parts....341
OPERATION....343
MACHINE VIEW ILLUSTRATIONS....344
OVERALL MACHINE VIEW....344
Controls And Gauges....345
Machine Monitor....346
DETAILED CONTROLS AND GAUGES....347
Monitoring System....347
Basic Operation Of Machine Monitor....348
Emergency Monitors....353
Caution Monitors....355
Basic Check Monitors....358
Meter Display Portion....360
Gauges And Meter....364
Monitor Switches Portion....368
Maintenance Selector Switch....384
SWITCHES....416
CONTROL LEVERS AND PEDALS....421
SUN ROOF....424
WINDSHIELD....424
EMERGENCY ESCAPE HAMMER....430
DOOR LOCK....430
CAP WITH LOCK....431
DRINK BOX....433
MAGAZINE BOX....433
ASHTRAY....433
AIR CONDITIONER CONTROLS....434
Air Conditioner Control Panel....434
Method Of Operation....439
Automatic Operation....439
Stopping Automatic Operation....440
Manual Operation....440
Stopping Manual Operation....442
Operation With Cold Air To Face And Warm Air To Feet....442
Defroster Operation....444
RADIO....447
Control Panel....447
Controls Of Radio....449
AUXILIARY ELECTRIC POWER....452
24V Power Source....452
12V Power Source....452
FUSE....453
FUSIBLE LINK....454
CONTROLLER....454
TOOL BOX....455
GREASE PUMP HOLDER....455
FIRE EXTINGUISHER....455
MACHINE OPERATIONS AND CONTROLS....456
Before Starting Engine....456
Walk-around Checks....456
Checks Before Starting....458
Adjustment....466
Seat Adjustment....466
Adjusting Angle Of Rear View Camera....468
Rear View Mirrors....470
Seat Belt....473
Operations Before Starting Engine....474
STARTING ENGINE....476
Turbo Protect Function....478
After Starting Engine....479
Breaking-in the New Machine....479
Engine Warm Up....480
Hydraulic System Warm-up....482
Operation After Completion Of Warming-up Operation....488
Stopping The Engine....490
MACHINE OPERATION....491
Preparations For Moving The Machine....491
Moving Machine Forward....492
Moving Machine Backward....493
Stopping Machine....494
Steering The Machine....495
Swinging....497
Work Equipment Controls And Operations....498
Working Mode....500
Prohibited Operations....502
General Operation Information....507
Traveling On Slopes....509
Escape From Mud....511
Recommended Applications....512
BUCKET REPLACEMENT AND INVERSION....514
Replacement....514
Inversion....516
PARKING MACHINE....518
MACHINE INSPECTION AFTER DAILY WORK....520
Locking....520
TRANSPORTATION....521
Transportation Procedure....521
Long Distance Transport Mode....522
Normal Mode Display....522
Long Distance Transport Mode Display....522
Loading And Unloading With Trailer....524
Loading....525
Securing Machine....528
Unloading....531
LIFTING MACHINE....533
TRANSPORTATION POSTURE....535
COLD WEATHER OPERATION....537
AFTER DAILY WORK COMPLETION....539
AFTER COLD WEATHER SEASON....539
LONG TERM STORAGE....540
Before Storage....540
During Storage....540
After Storage....541
Starting Machine After Long-term Storage....541
TROUBLES AND ACTIONS....542
Running Out Of Fuel....542
Phenomena That Are Not Failures....543
Towing The Machine....544
Lightweight Towing Hole....545
Severe Job Condition....545
Discharged Battery....546
Starting Engine With Booster Cables....548
OTHER TROUBLE....550
Electrical System....550
Chassis....551
Engine....552
Electronic Control System....553
MAINTENANCE....555
MAINTENANCE INFORMATION....556
OUTLINE OF SERVICE....558
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....558
Oil....558
Fuel....559
Coolant And Water For Dilution....559
Grease....560
Carrying Out KOWA (Komatsu Oil Wear Analysis)....560
KOWA Analysis Items....560
Oil Sampling....561
Storing Oil And Fuel....561
Filters....561
Electric System Maintenance....561
WEAR PARTS....562
Wear Parts List....562
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....563
TIGHTENING TORQUE SPECIFICATIONS....566
Tightening Torque List....566
SAFETY CRITICAL PARTS....567
Safety Critical Parts List....567
MAINTENANCE SCHEDULE....568
Maintenance Schedule Chart....568
Maintenance Interval For Hydraulic Breaker....570
MAINTENANCE PROCEDURE....571
Initial 1000 Hours Maintenance (Only After The First 1000 Hours)....571
When Required....572
Check, Clean And Replace Air Cleaner Element....572
Clean Inside Of Cooling System....578
Check And Tighten Track Shoe Bolts....582
Check And Adjust Track Tension....583
Replace Bucket Teeth (Vertical Pin Type)....585
Replace Bucket Teeth (Horizontal Pin Type)....588
Replace Bucket Side Cutter, Shroud....590
Adjust Bucket Clearance....591
Check Window Washer Fluid Level, Add Fluid....592
Check And Maintenance Air Conditioner....593
Wash Washable Floor....594
Check Gas Spring....597
Bleeding Air From Hydraulic System....598
Check Before Starting....600
Every 50 Hours Maintenance....601
Lubricating....601
Every 250 Hours Maintenance....602
Lubricate Swing Circle....602
Check Oil Level In Swing Machinery Case, Add Oil....603
Check Oil Level In Final Drive Case, Add Oil....604
Check Level Of Battery Electrolyte....605
Check Air Conditioner Compressor Belt Tension, Adjust....607
Every 500 Hours Maintenance....608
Lubricating....608
Replace Fuel Pre-filter Cartridge....610
Check Swing Pinion Grease Level, Add Grease....613
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge....614
Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins And Condenser Fins....616
Clean Air Conditioner Fresh/Recirc Filters....618
Replace Breather Element In Hydraulic Tank....619
Replace Hydraulic Tank Additional Breather Element....620
Every 1000 Hours Maintenance....621
Replace Fuel Main Filter Cartridge....621
Replace Hydraulic Oil Filter Element....623
Change Oil In Swing Machinery Case....624
Check Oil Level In Damper Case, Add Oil....625
Check All Tightening Points Of Engine Exhaust Pipe Clamps....625
Check Fan Belt And Alternator Drive Belt Tension, Replace....625
Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)....625
Replace Corrosion Resistor Cartridge....626
Every 2000 Hours Maintenance....627
Change Oil In Final Drive Case....627
Clean Hydraulic Tank Strainer....628
Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)....629
Checking Function Of Accumulator....630
Releasing Pressure In Hydraulic Circuit....632
Check Alternator....633
Check Engine Valve Clearance, Adjust....633
Check Vibration Damper....633
Every 4000 Hours Maintenance....634
Check Water Pump....634
Check Starting Motor....634
Replace Accumulator (For Control Circuit)....635
Check For Looseness Of High-pressure Piping Clamp, Hardening Of Rubber....636
Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber....636
Every 5000 Hours Maintenance....637
Change Oil In Hydraulic Tank....637
Every 8000 Hours Maintenance....639
Replace High-pressure Piping Clamp....639
Replace Fuel Spray Prevention Cap....639
SPECIFICATIONS....641
SPECIFICATIONS....642
OPTIONS, ATTACHMENTS....645
GENERAL PRECAUTIONS FOR SAFETY....646
Precautions When Selecting....646
Read The Instruction Manual Thoroughly....646
Precautions When Removing Or Installing....646
Precautions When Using....646
BUCKET WITH HOOK....647
Hook Condition....647
Prohibited Operations....647
MACHINE READY FOR ATTACHMENT....648
Locations....648
ATTACHMENT REMOVAL AND INSTALLATION....658
Attachment Removal....658
Attachment Installation....660
ATTACHMENT OPERATIONS....662
Long Term Storage....663
Specifications....663
ATTACHMENT GUIDE....664
Attachment Combinations....665
Track Shoes Selection....666
Selecting Shoes....666
RECOMMENDED ATTACHMENT OPERATIONS....667
Hydraulic Breaker....667
HANDLING MACHINES EQUIPPED WITH KOMTRAX....672
CEAM008802 - Hydraulic Excavator GALEO PC300LC-7L, PC300HD-7L Operation & Maintenance Manual....673
COVER....673
INTRODUCTION....677
FOREWORD....678
SAFETY INFORMATION....679
SIGNAL WORDS....679
OTHER SIGNAL WORDS....679
INTRODUCTION....680
DIRECTIONS OF MACHINE....681
PRODUCT INFORMATION....682
MACHINE SERIAL NUMBER PLATE....682
ENGINE SERIAL NUMBER PLATE....682
SERVICE METER LOCATION....683
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....683
TABLE OF CONTENTS....684
SAFETY....695
SAFETY LABELS....696
SAFETY INFORMATION....702
SAFETY RULES....702
IF ABNORMALITIES ARE FOUND....702
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....702
FIRE EXTINGUISHER AND FIRST AID KIT....702
SAFETY EQUIPMENT....703
KEEP MACHINE CLEAN....703
KEEP OPERATOR'S COMPARTMENT CLEAN....703
LEAVING OPERATOR'S SEAT WITH LOCK....703
HANDRAILS AND STEPS....704
MOUNTING AND DISMOUNTING....704
NO PERSONS ON ATTACHMENTS....704
BURN PREVENTION....704
HOT COOLANT....704
HOT OIL....704
FIRE PREVENTION AND EXPLOSION PREVENTION....705
FIRE CAUSED BY FUEL OR OIL....705
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL....705
FIRE COMING FROM ELECTRIC WIRING....705
FIRE COMING FROM HYDRAULIC LINE....705
EXPLOSION CAUSED BY LIGHTING EQUIPMENT....706
ACTION IF FIRE OCCURS....706
WINDSHIELD WASHER FLUID....706
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....706
ATTACHMENT INSTALLATION....706
ATTACHMENT COMBINATIONS....706
CAB WINDOW GLASS....707
UNAUTHORIZED MODIFICATIONS....707
SAFETY AT JOBSITE....707
WORKING ON LOOSE GROUND....707
DISTANCE TO HIGH VOLTAGE CABLES....708
ENSURE GOOD VISIBILITY....708
VENTILATION FOR ENCLOSED AREA....709
SIGNALMAN'S SIGNAL AND SIGNS....709
EMERGENCY EXIT FROM OPERATOR'S CAB....709
ASBESTOS DUST HAZARD PREVENTION....709
SAFE MACHINE OPERATION....710
STARTING ENGINE....710
CHECKS BEFORE STARTING ENGINE....710
SAFETY RULES FOR STARTING ENGINE....710
STARTING ENGINE IN COLD WEATHER....710
OPERATION....711
CHECKS AFTER STARTING ENGINE, BEFORE OPERATION....711
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....711
SAFETY RULES FOR TRAVELING....712
TRAVELING ON SLOPES....712
OPERATIONS ON SLOPES....713
PROHIBITED OPERATIONS....713
OPERATIONS ON SNOW....714
PARKING MACHINE....715
TRANSPORTATION....715
SHIPPING THE MACHINE....715
BATTERY....716
BATTERY HAZARD PREVENTION....716
STARTING ENGINE WITH BOOSTER CABLES....717
TOWING....717
SAFETY RULES FOR TOWING....717
LIFTING OBJECTS WITH THE BUCKET....718
SAFETY RULES FOR LIFTING OBJECTS....718
SAFETY MAINTENANCE INFORMATION....718
WARNING TAG....718
KEEP WORK PLACE CLEAN AND TIDY....719
APPOINT LEADER WHEN WORKING WITH OTHERS....719
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....719
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....720
PROPER TOOLS....720
ACCUMULATOR....720
PERSONNEL....721
ATTACHMENTS....721
NOISE....721
WHEN USING HAMMER....722
WELDING....722
REMOVING BATTERY TERMINALS....722
ADJUSTING TRACK TENSION....722
DO NOT DISASSEMBLE RECOIL SPRINGS....722
SAFETY RULES FOR HIGH PRESSURE OIL....723
SAFETY HANDLING HIGH PRESSURE HOSES....723
WASTE MATERIALS....723
AIR CONDITIONER MAINTENANCE....724
COMPRESSED AIR....724
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....724
OPERATION....725
GENERAL VIEW....726
GENERAL VIEW OF MACHINE....726
GENERAL VIEW CONTROLS AND GAUGES....727
EXPLANATION OF COMPONENTS....728
MACHINE MONITOR....728
BASIC OPERATION OF MACHINE MONITOR....729
IF THERE IS A PROBLEM WHEN STARTING THE ENGINE....729
IF ANY PROBLEM OCCURS DURING OPERATION....730
BASIC CHECK ITEMS....731
RADIATOR WATER LEVEL MONITOR....731
ENGINE OIL LEVEL MONITOR....732
MAINTENANCE INTERVAL MONITOR....732
CAUTION ITEMS....733
CHARGE MONITOR....733
FUEL LEVEL MONITOR....734
AIR CLEANER CLOGGING MONITOR....734
ENGINE WATER TEMPERATURE MONITOR....734
HYDRAULIC OIL TEMPERATURE MONITOR....734
EMERGENCY STOP ITEMS....735
ENGINE WATER TEMPERATURE MONITOR....735
HYDRAULIC OIL TEMPERATURE MONITOR....736
ENGINE OIL PRESSURE MONITOR....736
METER DISPLAY PORTION....737
PILOT DISPLAY....737
SWING LOCK MONITOR....737
METERS....739
MONITOR SWITCHES....741
WORKING MODE SELECTOR SWITCH (BASIC SWITCH)....742
AUTO DECELERATION SWITCH....742
TRAVEL SPEED SELECTOR SWITCH....743
WIPER SWITCH....744
WINDOW WASHER SWITCH....745
MAINTENANCE SWITCH....745
SELECT SWITCH....747
BACK SWITCH....748
UP SWITCH, DOWN SWITCH....749
INPUT CONFIRMATION SWITCH....749
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH....749
SWITCHES....751
STARTING SWITCH....751
FUEL CONTROL DIAL....752
CIGARETTE LIGHTER....752
SWING LOCK SWITCH....752
LAMP SWITCH....753
ALARM BUZZER STOP SWITCH....753
MACHINE PUSH UP SWITCH....753
HORN SWITCH....753
KNOB SWITCH....754
ROOM LAMP SWITCH....754
AUXILIARY PUMP DRIVE SWITCH....754
AUXILIARY FUEL SOLENOID DRIVE SWITCH....755
SWING BRAKE CANCEL SWITCH....755
ROTATING LAMP SWITCH....755
CONTROL LEVERS, PEDALS....756
SAFETY LOCK LEVER....756
TRAVEL LEVERS....757
WORK EQUIPMENT CONTROL LEVER....758
CEILING WINDOW....759
WHEN OPENING....759
WHEN CLOSING....759
FRONT WINDOW....759
WHEN CLOSING....761
FRONT BOTTOM WINDOW....763
EMERGENCY EXIT FROM OPERATOR'S CAB....763
DOOR LOCK....764
CAP, COVER WITH LOCK....764
METHOD OF OPENING AND CLOSING CAP WITH LOCK....764
METHOD OF OPENING AND CLOSING COVER WITH LOCK....765
HOT AND COOL BOX....765
MAGAZINE BOX WITH CUP HOLDER....765
ASHTRAY....765
AIR CONDITIONER....766
GENERAL LOCATION OF CONTROL PANEL....766
METHOD OF OPERATION....770
PRECAUTIONS WHEN USING AIR CONDITIONER....776
CHECK, MAINTAIN MACHINE AIR CONDITIONER....776
RADIO....778
EXPLANATION OF COMPONENTS....778
OPERATION....781
POWER PICK UP PORT....783
24V POWER SOURCE....783
12V POWER SOURCE....783
FUSE....784
FUSE CAPACITIES AND CIRCUIT NAMES....784
FUSIBLE LINK....784
CONTROLLER (COMPUTER)....785
TOOLBOX....785
GREASE GUN HOLDER....785
HANDLING THE ACCUMULATOR....786
RELEASING PRESSURE IN CONTROL CIRCUIT....786
MACHINE OPERATIONS AND CONTROLS....787
BEFORE STARTING ENGINE....787
WALK AROUND CHECKS....787
CHECKS BEFORE STARTING....788
ADJUSTMENTS BEFORE OPERATION....793
ADJUSTMENT OF MIRRORS....794
SEAT BELT....795
BEFORE STARTING ENGINE....795
STARTING ENGINE....798
NORMAL STARTING....798
STARTING ENGINE IN COLD WEATHER....799
AFTER STARTING ENGINE....802
BREAKING IN A NEW MACHINE....802
WARM UP OPERATION....802
AUTOMATIC WARM UP OPERATION....806
STOPPING THE ENGINE....810
CHECK AFTER SHUTTING OFF ENGINE....810
MACHINE OPERATION....811
PREPARATIONS FOR MOVING THE MACHINE....811
MOVING MACHINE FORWARD....812
MOVING MACHINE BACKWARD....812
STOPPING MACHINE....813
STEERING THE MACHINE....814
STEERING THE MACHINE WHEN STOPPED....814
CHANGING DIRECTION OF THE MACHINE....814
COUNTER ROTATION TURN, SPIN TURN....815
SWINGING....816
EQUIPMENT CONTROLS AND OPERATIONS....817
OPERATING WORKING MODE....818
WORKING MODE....818
ONE TOUCH POWER MAX SWITCH....818
PROHIBITED OPERATIONS....819
OPERATIONS USING SWING FORCE....819
OPERATIONS USING TRAVEL FORCE....819
OPERATIONS USING CYLINDER STROKE ENDS....819
OPERATIONS USING BUCKET DROPPING FORCE....820
OPERATIONS USING MACHINE DROPPING FORCE....820
DIGGING HARD ROCKY GROUND....820
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL....820
GENERAL OPERATION INFORMATION....821
TRAVELING....821
HIGH SPEED TRAVEL....821
PERMISSIBLE WATER DEPTH....821
TRAVELING ON SLOPES....822
TRAVELING DOWNHILL....823
ENGINE STOPPED ON SLOPE....823
PRECAUTIONS ON SLOPES....823
ESCAPE FROM MUD....824
ONE SIDE OF TRACK STUCK....824
BOTH SIDES OF TRACKS STUCK....824
RECOMMENDED APPLICATIONS....825
BACKHOE WORK....825
SHOVEL WORK....825
DITCHING WORK....825
LOADING WORK....826
REPLACEMENT AND INVERSION OF BUCKET....827
REPLACEMENT....827
INVERSION....828
PARKING THE MACHINE....830
CHECK AFTER FINISHING WORK....831
LOCKING....832
TRANSPORTATION....832
TRANSPORTATION PROCEDURE....832
LOADING....834
LOADING AND UNLOADING WITH TRAILER....833
SECURING THE MACHINE....836
UNLOADING....837
LIFTING THE MACHINE....840
COLD WEATHER OPERATION....841
FUEL AND LUBRICANTS....841
COOLING SYSTEM COOLANT....841
BATTERY....842
AFTER OPERATIONS....843
AFTER COLD WEATHER SEASON....843
LONG TERM STORAGE....844
BEFORE STORAGE....844
DURING STORAGE....844
AFTER STORAGE....844
TROUBLESHOOTING....845
AFTER RUNNING OUT OF FUEL....845
PHENOMENA THAT ARE NOT FAILURES....845
TOWING THE MACHINE....846
LIGHTWEIGHT TOWING HOOK....846
PRECAUTIONS ON PARTICULAR JOB SITES....846
DISCHARGED BATTERY....847
REMOVAL AND INSTALLATION OF BATTERY....847
BATTERY CHARGES....848
STARTING ENGINE WITH BOOSTER CABLES....848
OTHER TROUBLE....850
ELECTRICAL SYSTEM....850
CHASSIS....851
ENGINE....852
ELECTRONIC CONTROL SYSTEM....853
MAINTENANCE....855
MAINTENANCE INFORMATION....856
SERVICE METER READING....856
GENUINE KOMATSU REPLACEMENT PARTS....856
GENUINE KOMATSU LUBRICANTS....856
WINDSHIELD WASHER FLUID....856
FRESH AND CLEAN LUBRICANTS....856
CHECK DRAINED OIL AND USED FILTER....856
FUEL STRAINER....856
WELDING INSTRUCTIONS....856
DO NOT DROP THINGS INSIDE MACHINE....856
DUSTY JOBSITE....857
AVOID MIXING LUBRICANTS....857
LOCKING THE INSPECTION COVERS....857
HYDRAULIC SYSTEM - AIR BLEEDING....857
HYDRAULIC HOSE INSTALLATION....857
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS....857
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE....858
LUBRICANTS, COOLANT AND FILTERS....858
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....858
OIL....858
FUEL....858
COOLING SYSTEM COOLANT....859
GREASE....859
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)....859
OIL AND FUEL STORAGE....860
FILTERS....860
ELECTRIC SYSTEM MAINTENANCE....861
HANDLING HYDRAULIC SYSTEM....861
WEAR PARTS LIST....862
USE OF FUEL, COOLANT AND LUBRICANTS....863
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS....863
TIGHTENING TORQUE SPECIFICATIONS....865
BOLT IDENTIFICATION CHART....865
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....867
SAFETY CRITICAL PARTS....867
MAINTENANCE SCHEDULE CHART....868
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....870
REPLACING HYDRAULIC ELEMENT....870
CHANGING OIL IN HYDRAULIC TANK....870
REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER....870
MAINTENANCE PROCEDURE....871
INITIAL 10 HOURS MAINTENANCE....871
LUBRICATION....871
INITIAL 250 HOURS MAINTENANCE....873
REPLACE THE FUEL FILTER CARTRIDGE....873
INITIAL 1000 HOURS MAINTENANCE....873
WHEN REQUIRED....874
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....874
CLEAN INSIDE OF COOLING SYSTEM....877
CHECK AND TIGHTEN TRACK SHOE BOLTS....879
CHECK AND ADJUST TRACK TENSION....879
CHECK ELECTRICAL INTAKE AIR HEATER....881
REPLACE THE BUCKET TEETH (PARABOLIC TEETH)....881
REPLACE THE BUCKET TEETH (SERIES 5 TEETH)....883
REPLACE THE BUCKET TEETH (KVX TEETH)....887
ADJUST BUCKET CLEARANCE....889
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....889
CHECK AND ADJUST AIR CONDITIONER....890
CLEANING CAB FLOOR....891
METHOD OF SETTING THE MACHINE ANGLE....893
BLEEDING AIR FROM HYDRAULIC SYSTEM....893
RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT....895
CHECK BEFORE STARTING....896
CHECK COOLANT LEVEL, ADD COOLANT....896
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL....896
CHECK FUEL LEVEL, ADD FUEL....897
DRAIN WATER, SEDIMENT FROM FUEL TANK....898
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR....898
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....899
CHECK ELECTRIC WIRING....900
CHECK HORN FUNCTION....900
EVERY 50 HOURS MAINTENANCE....901
LUBRICATION....901
EVERY 250 HOURS MAINTENANCE....902
LUBRICATION....902
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL....903
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....903
CHECK LEVEL OF BATTERY ELECTROLYTE....904
LUBRICATE SWING CIRCLE (2 POINTS)....906
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT....906
EVERY 500 HOURS MAINTENANCE....907
PREVIOUS MAINTENANCE....907
LUBRICATION....907
REPLACE THE FUEL FILTER CARTRIDGE....908
CHECK THE SWING PINION GREASE LEVEL, ADD GREASE....909
CHANGE ENGINE OIL, REPLACE FILTER CARTRIDGE....910
CLEAN AND INSPECT RADIATOR, OIL COOLER, AFTERCOOLER AND CONDENSER FINS....912
CLEAN AIR CONDITIONER SYSTEM AIR FILTERS....913
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK CAP....914
EVERY 1000 HOURS MAINTENANCE....915
PREVIOUS MAINTENANCE....915
REPLACE HYDRAULIC FILTER ELEMENT....915
CHANGE OIL IN SWING MACHINERY CASE....916
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL....916
REPLACE THE CORROSION RESISTOR CARTRIDGE....917
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER....917
CHECK PLAY OF TURBOCHARGER ROTOR....917
CHECK FAN BELT TENSION AND REPLACE FAN BELT....917
EVERY 2000 HOURS MAINTENANCE....918
PREVIOUS MAINTENANCE....918
CHANGE OIL IN FINAL DRIVE CASE....918
CLEAN HYDRAULIC TANK STRAINER....918
CLEAN THE ENGINE BREATHER....919
CLEAN, CHECK TURBOCHARGER....919
CHECK ALTERNATOR, STARTING MOTOR....919
CHECK ENGINE VALVE CLEARANCE, ADJUST....919
CHECK VIBRATION DAMPER....919
EVERY 4000 HOURS MAINTENANCE....920
PREVIOUS MAINTENANCE....920
CHECK WATER PUMP....920
EVERY 5000 HOURS MAINTENANCE....921
PREVIOUS MAINTENANCE....921
CHANGE OIL IN HYDRAULIC TANK....921
SPECIFICATIONS....923
SPECIFICATIONS....924
DIMENSIONS....924
WORKING RANGE....926
LIFTING CAPACITY....928
OPTIONS, ATTACHMENTS....935
GENERAL PRECAUTIONS....936
SAFETY RELATED PRECAUTIONS....936
PRECAUTIONS WHEN INSTALLING ATTACHMENTS....937
HANDLING THE BUCKET WITH HOOK....938
CHECKING FOR DAMAGE TO BUCKET HOOK....938
PROHIBITED OPERATIONS....938
PRECAUTIONS DURING OPERATIONS....938
MACHINES READY FOR ATTACHMENTS....939
EXPLANATION OF COMPONENTS....939
STOP VALVE....939
SELECTOR VALVE....940
ATTACHMENT CONTROL PEDAL....940
LOCK PIN....940
ADDITIONAL FILTER FOR BREAKER....941
ACCUMULATOR....941
HYDRAULIC CIRCUIT....941
SWITCHING THE HYDRAULIC CIRCUIT....941
ADJUSTING OIL FLOW....942
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT....942
HYDRAULIC CIRCUIT CONNECTION....942
PATH OF OIL....943
REPLACE ADDITIONAL BREAKER FILTER ELEMENT....943
ATTACHMENT INSTALLATION AND REMOVAL....944
REMOVAL....944
INSTALLATION....945
OPERATION....946
WHEN USING BREAKER....946
WHEN USING CRUSHER OR OTHER GENERAL ATTACHMENT....947
LONG TERM STORAGE....948
SPECIFICATIONS....948
COMBINATIONS OF WORK EQUIPMENT FOR PC300LC-7....949
ATTACHMENT OPERATIONS....950
HYDRAULIC BREAKER....950
MAIN APPLICATIONS....950
PROHIBITED OPERATIONS....951
GREASING POSITION FOR HYDRAULIC BREAKER....953
CEAM012300 - Logging Excavator GALEO PC300LL-7L Operation & Maintenance Manual....957
COVER....957
INTRODUCTION....963
FOREWORD....964
SAFETY INFORMATION....965
SIGNAL WORDS....965
OTHER SIGNAL WORDS....965
INTRODUCTION....966
INTENDED USE....966
BREAKING IN THE MACHINE....966
DIRECTIONS OF MACHINE....967
PRODUCT INFORMATION....968
MACHINE SERIAL NUMBER PLATE....968
ENGINE SERIAL NUMBER PLATE....968
SERVICE METER LOCATION....969
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....969
TABLE OF CONTENTS....970
SAFETY....979
SAFETY DECALS....980
NORMAL EXCAVATOR DECALS....980
UNIQUE SAFETY DECALS FOR LOG LOADER AND ROAD BUILDER EXCAVATORS....986
SAFETY INFORMATION....992
SAFETY RULES....992
IF ABNORMALITIES ARE FOUND....992
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....992
FIRE EXTINGUISHER AND FIRST AID KIT....992
SAFETY EQUIPMENT....992
KEEP MACHINE CLEAN....993
KEEP OPERATOR'S COMPARTMENT CLEAN....993
LEAVING OPERATOR'S SEAT WITH LOCK....993
INJURY FROM WORK EQUIPMENT....993
HANDRAILS AND STEPS....994
MOUNTING AND DISMOUNTING....994
NO PERSONS ON ATTACHMENTS....994
BURN PREVENTION....994
HOT COOLANT....994
HOT OIL....994
FIRE PREVENTION AND EXPLOSION PREVENTION....995
FIRE CAUSED BY FUEL OR OIL....995
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL....995
FIRE COMING FROM ELECTRIC WIRING....995
FIRE COMING FROM HYDRAULIC LINE....995
EXPLOSION CAUSED BY LIGHTING EQUIPMENT....995
ACTION IF FIRE OCCURS....996
WINDSHIELD WASHER FLUID....996
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....996
PROTECTION AGAINST FALLING OR FLYING OBJECTS....997
ATTACHMENT INSTALLATION....997
ATTACHMENT COMBINATIONS....997
CAB WINDOW GLASS....997
UNAUTHORIZED MODIFICATIONS....998
SAFETY AT JOBSITE....998
WORKING ON LOOSE GROUND....998
DISTANCE TO HIGH VOLTAGE CABLES....999
ENSURE GOOD VISIBILITY....999
VENTILATION FOR ENCLOSED AREA....1000
SIGNALMAN'S SIGNAL AND SIGNS....1000
EMERGENCY EXIT FROM OPERATOR'S CAB....1000
ASBESTOS DUST HAZARD PREVENTION....1000
SAFE MACHINE OPERATION....1002
STARTING ENGINE....1002
CHECKS BEFORE STARTING ENGINE....1002
SAFETY RULES FOR STARTING ENGINE....1002
STARTING ENGINE IN COLD WEATHER....1002
OPERATION....1003
CHECKS AFTER STARTING ENGINE, BEFORE OPERATION....1003
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....1003
SAFETY RULES FOR TRAVELING....1004
TRAVELING ON SLOPES....1004
OPERATIONS ON SLOPES....1005
PROHIBITED OPERATIONS....1005
OPERATIONS ON SNOW....1006
PARKING MACHINE....1007
TRANSPORTATION....1007
SHIPPING THE MACHINE....1007
BATTERY....1008
BATTERY HAZARD PREVENTION....1008
STARTING ENGINE WITH BOOSTER CABLES....1009
TOWING....1009
SAFETY RULES FOR TOWING....1009
LIFTING OBJECTS WITH BUCKET....1010
SAFETY RULES FOR LIFTING OBJECTS....1010
SAFETY MAINTENANCE INFORMATION....1011
WARNING TAG....1011
KEEP WORK PLACE CLEAN AND TIDY....1011
APPOINT LEADER WHEN WORKING WITH OTHERS....1011
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....1011
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....1012
PROPER TOOLS....1012
ACCUMULATOR....1012
PERSONNEL....1012
ATTACHMENTS....1013
NOISE....1013
WHEN USING HAMMER....1013
WELDING....1013
REMOVING BATTERY TERMINALS....1013
ADJUSTING TRACK TENSION....1014
DO NOT DISASSEMBLE RECOIL SPRINGS....1014
SAFETY RULES FOR HIGH PRESSURE OIL....1014
SAFETY HANDLING HIGH PRESSURE HOSES....1014
WASTE MATERIALS....1015
AIR CONDITIONER MAINTENANCE....1015
COMPRESSED AIR....1015
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1015
OPERATION....1017
GENERAL VIEW....1018
GENERAL VIEW OF MACHINE....1018
GENERAL VIEW CONTROLS AND GAUGES....1019
EXPLANATION OF COMPONENTS....1020
MACHINE MONITOR....1020
BASIC OPERATION OF MACHINE MONITOR....1021
IF THERE IS ABNORMALITY WHEN STARTING ENGINE....1021
IF ANY ABNORMALITY OCCURS DURING OPERATION....1022
BASIC CHECK ITEMS....1023
RADIATOR WATER LEVEL MONITOR....1023
ENGINE OIL LEVEL MONITOR....1024
MAINTENANCE INTERVAL MONITOR....1024
CAUTION ITEMS....1025
CHARGE MONITOR....1025
FUEL LEVEL MONITOR....1026
AIR CLEANER CLOGGING MONITOR....1026
ENGINE WATER TEMPERATURE MONITOR....1026
HYDRAULIC OIL TEMPERATURE MONITOR....1026
EMERGENCY STOP ITEMS....1027
ENGINE WATER TEMPERATURE MONITOR....1027
HYDRAULIC OIL TEMPERATURE MONITOR....1028
ENGINE OIL PRESSURE MONITOR....1028
METER DISPLAY PORTION....1029
PILOT DISPLAY....1029
SWING LOCK MONITOR....1029
METERS....1031
MONITOR SWITCHES....1033
WORKING MODE SELECTOR SWITCH (BASIC SWITCH)....1034
AUTO DECELERATION SWITCH....1034
TRAVEL SPEED SELECTOR SWITCH....1035
WIPER SWITCH....1036
WINDOW WASHER SWITCH....1037
MAINTENANCE SWITCH....1037
SELECT SWITCH....1039
BACK SWITCH....1040
UP SWITCH, DOWN SWITCH....1041
INPUT CONFIRMATION SWITCH....1041
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH....1041
SWITCHES....1044
STARTING SWITCH....1045
FUEL CONTROL DIAL....1046
CIGARETTE LIGHTER....1046
SWING LOCK SWITCH....1046
LAMP SWITCH....1047
ALARM BUZZER STOP SWITCH....1047
MACHINE PUSH UP SWITCH....1047
HORN SWITCH....1047
LOG LOADER GRAPPLE ROTATION CW SWITCH....1048
LOG LOADER GRAPPLE CLOSE SWITCH....1048
POWER MAX SWITCH....1048
LOG LOADER GRAPPLE ROTATION CCW SWITCH....1048
LOG LOADER GRAPPLE OPEN SWITCH....1048
ROOM LAMP SWITCH....1048
EMERGENCY PUMP DRIVE SWITCH....1049
EMERGENCY FUEL SOLENOID DRIVE SWITCH....1049
SWING BRAKE CANCEL SWITCH....1049
CONTROL LEVERS, PEDALS....1050
SAFETY LOCK LEVER....1050
TRAVEL LEVERS....1051
WORK EQUIPMENT CONTROL LEVER....1052
CEILING WINDOW....1053
WHEN OPENING....1053
WHEN CLOSING....1053
FRONT WINDOW....1053
WHEN CLOSING....1055
FRONT BOTTOM WINDOW....1057
EMERGENCY EXIT FROM OPERATOR'S CAB - FROM INSIDE....1058
DOOR LOCK....1059
CAP, COVER WITH LOCK....1059
METHOD OF OPENING AND CLOSING CAP WITH LOCK....1059
METHOD OF OPENING AND CLOSING COVER WITH LOCK....1060
HOT AND COOL BOX....1060
MAGAZINE BOX WITH CUP HOLDER....1060
ASHTRAY....1060
AIR CONDITIONER....1061
GENERAL LOCATION OF CONTROL PANEL....1061
METHOD OF OPERATION....1065
PRECAUTIONS WHEN USING AIR CONDITIONER....1071
CHECK, MAINTAIN MACHINE AIR CONDITIONER....1071
RADIO....1073
EXPLANATION OF COMPONENTS....1073
METHOD OF OPERATION....1074
POWER PICK UP PORT....1077
24V POWER SOURCE....1077
12V POWER SOURCE....1077
FUSE....1078
FUSE CAPACITIES AND CIRCUIT NAMES....1078
FUSIBLE LINK....1078
CONTROLLER (COMPUTER)....1079
TOOLBOX....1079
GREASE GUN HOLDER....1079
HANDLING THE ACCUMULATOR....1080
RELEASING PRESSURE IN CONTROL CIRCUIT....1080
MACHINE OPERATIONS AND CONTROLS....1081
BEFORE STARTING ENGINE....1081
WALK AROUND CHECKS....1081
CHECKS BEFORE STARTING....1082
ADJUSTMENTS BEFORE OPERATION....1087
ADJUSTMENT OF MIRRORS....1088
SEAT BELT....1089
BEFORE STARTING ENGINE....1089
STARTING ENGINE....1092
NORMAL STARTING....1092
STARTING ENGINE IN COLD WEATHER....1093
AFTER STARTING ENGINE....1096
BREAKING IN A NEW MACHINE....1096
WARM UP OPERATION....1096
AUTOMATIC WARM UP OPERATION....1100
STOPPING THE ENGINE....1104
CHECK AFTER SHUTTING OFF ENGINE....1105
MACHINE OPERATION....1106
PREPARATIONS FOR MOVING THE MACHINE....1106
MOVING MACHINE FORWARD....1107
MOVING MACHINE BACKWARD....1107
STOPPING MACHINE....1108
STEERING THE MACHINE....1109
STEERING THE MACHINE WHEN STOPPED....1109
CHANGING DIRECTION OF THE MACHINE....1109
COUNTER ROTATION TURN, SPIN TURN....1110
SWINGING....1111
EQUIPMENT CONTROLS AND OPERATIONS....1112
OPERATING WORKING MODE....1113
WORKING MODE....1113
ONE TOUCH POWER MAX SWITCH....1113
PROHIBITED OPERATIONS....1114
OPERATIONS USING SWING FORCE....1114
OPERATIONS USING TRAVEL FORCE....1114
OPERATIONS USING CYLINDER STROKE ENDS....1114
OPERATIONS USING BUCKET DROPPING FORCE....1115
OPERATIONS USING MACHINE DROPPING FORCE....1115
DIGGING HARD ROCKY GROUND....1115
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL....1115
GENERAL OPERATION INFORMATION....1116
TRAVELING....1116
HIGH SPEED TRAVEL....1116
PERMISSIBLE WATER DEPTH....1116
TRAVELING ON SLOPES....1117
TRAVELING DOWNHILL....1118
ENGINE STOPPED ON SLOPE....1118
PRECAUTIONS ON SLOPES....1118
ESCAPE FROM MUD....1119
ONE SIDE OF TRACK STUCK....1119
BOTH SIDES OF TRACKS STUCK....1119
ROAD BUILDER RECOMMENDED APPLICATIONS....1120
BACKHOE WORK....1120
SHOVEL WORK....1120
DITCHING WORK....1120
LOADING WORK....1121
REPLACEMENT AND INVERSION OF BUCKET....1122
REPLACEMENT....1122
INVERSION....1123
PARKING THE MACHINE....1125
CHECK AFTER FINISHING WORK....1127
LOCKING....1128
TRANSPORTATION....1129
TRANSPORTATION PROCEDURE....1129
LOADING AND UNLOADING WITH TRAILER....1130
LOADING....1130
SECURING THE MACHINE....1133
UNLOADING....1137
LIFTING THE MACHINE....1140
COLD WEATHER OPERATION....1141
FUEL AND LUBRICANTS....1141
COOLING SYSTEM COOLANT....1141
BATTERY....1142
AFTER OPERATIONS....1143
AFTER COLD WEATHER SEASON....1143
LONG TERM STORAGE....1144
BEFORE STORAGE....1144
DURING STORAGE....1144
AFTER STORAGE....1144
TROUBLESHOOTING....1145
AFTER RUNNING OUT OF FUEL....1145
PHENOMENA THAT ARE NOT FAILURES....1145
TOWING THE MACHINE....1146
LIGHTWEIGHT TOWING HOOK....1146
PRECAUTIONS ON PARTICULAR JOB SITES....1146
DISCHARGED BATTERY....1147
REMOVAL AND INSTALLATION OF BATTERY....1147
BATTERY CHARGES....1147
STARTING ENGINE WITH BOOSTER CABLES....1148
OTHER TROUBLE....1150
ELECTRICAL SYSTEM....1150
CHASSIS....1151
ENGINE....1152
ELECTRONIC CONTROL SYSTEM....1153
MAINTENANCE....1155
MAINTENANCE INFORMATION....1156
SERVICE METER READING....1156
GENUINE KOMATSU REPLACEMENT PARTS....1156
GENUINE KOMATSU LUBRICANTS....1156
WINDSHIELD WASHER FLUID....1156
FRESH AND CLEAN LUBRICANTS....1156
CHECK DRAINED OIL AND USED FILTER....1156
FUEL STRAINER....1156
WELDING INSTRUCTIONS....1156
DO NOT DROP THINGS INSIDE MACHINE....1156
DUSTY JOBSITE....1157
AVOID MIXING LUBRICANTS....1157
LOCKING THE INSPECTION COVERS....1157
HYDRAULIC SYSTEM - AIR BLEEDING....1157
HYDRAULIC HOSE INSTALLATION....1157
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS....1157
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE....1158
LUBRICANTS, COOLANT AND FILTERS....1158
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....1158
OIL....1158
FUEL....1158
COOLING SYSTEM COOLANT....1159
GREASE....1159
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)....1159
OIL AND FUEL STORAGE....1160
FILTERS....1160
ELECTRIC SYSTEM MAINTENANCE....1161
HANDLING HYDRAULIC SYSTEM....1161
WEAR PARTS LIST....1162
USE OF FUEL, COOLANT AND LUBRICANTS....1163
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS....1163
TIGHTENING TORQUE SPECIFICATIONS....1165
BOLT IDENTIFICATION CHART....1165
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1167
SAFETY CRITICAL PARTS....1167
MAINTENANCE SCHEDULE CHART....1168
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....1170
REPLACING HYDRAULIC ELEMENT....1170
CHANGING OIL IN HYDRAULIC TANK....1170
REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER....1170
MAINTENANCE PROCEDURE....1171
INITIAL 10 HOURS MAINTENANCE....1171
LUBRICATION ROAD BUILDER MACHINE....1171
INITIAL 250 HOURS MAINTENANCE....1173
REPLACE THE FUEL FILTER CARTRIDGE....1173
INITIAL 1000 HOURS MAINTENANCE....1173
CHECK ENGINE VALVE CLEARANCE, ADJUST....1218
WHEN REQUIRED....1174
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....1174
CLEAN INSIDE OF COOLING SYSTEM....1177
CHECK AND TIGHTEN TRACK SHOE BOLTS....1179
CHECK AND ADJUST TRACK TENSION....1179
CHECK ELECTRICAL INTAKE AIR HEATER....1181
REPLACE THE BUCKET TEETH (PARABOLIC TEETH)....1181
REPLACE THE BUCKET TEETH (SERIES 5 TEETH)....1183
REPLACE THE BUCKET TEETH (KVX TEETH)....1187
ADJUST BUCKET CLEARANCE....1189
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....1189
CHECK AND ADJUST AIR CONDITIONER....1190
CLEANING CAB FLOOR....1191
METHOD OF SETTING THE MACHINE ANGLE....1193
BLEEDING AIR FROM HYDRAULIC SYSTEM....1193
RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT....1195
CHECK BEFORE STARTING....1196
CHECK COOLANT LEVEL, ADD COOLANT....1196
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL....1196
CHECK FUEL LEVEL, ADD FUEL....1197
DRAIN WATER, SEDIMENT FROM FUEL TANK....1198
CHECK FOR WATER AND SEDIMENT IN WATER SEPARA TOR....1199
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....1200
CHECK ELECTRIC WIRING....1201
CHECK HORN FUNCTION....1201
EVERY 250 HOURS MAINTENANCE....1201
LUBRICATION....1201
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL....1201
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....1202
CHECK LEVEL OF BATTERY ELECTROLYTE....1203
LUBRICATE SWING CIRCLE (3 POINTS)....1205
CHECK, ADJUST TENSION OF AIR CONDITIONER COM PRESSOR BELT....1205
EVERY 500 HOURS MAINTENANCE....1206
PREVIOUS MAINTENANCE....1206
LUBRICATION....1206
REPLACE THE FUEL FILTER CARTRIDGE....1206
CHECK THE SWING PINION GREASE LEVEL, ADD GREASE....1207
CHANGE ENGINE OIL, REPLACE FILTER CARTRIDGE....1208
CLEAN AND INSPECT RADIATOR, OIL COOLER, AFTERCOOLER AND CONDENSER FINS....1210
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM....1211
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK CAP....1212
EVERY 1000 HOURS MAINTENANCE....1213
PREVIOUS MAINTENANCE....1213
REPLACE HYDRAULIC FILTER ELEMENT....1213
CHANGE OIL IN SWING MACHINERY CASE....1214
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL....1214
REPLACE THE CORROSION RESISTOR CARTRIDGE....1215
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER....1215
CHECK PLAY OF TURBOCHARGER ROTOR....1215
CHECK FAN BELT TENSION AND REPLACE FAN BELT....1215
EVERY 2000 HOURS MAINTENANCE....1216
PREVIOUS MAINTENANCE....1216
CHANGE OIL IN FINAL DRIVE CASE....1216
CLEAN HYDRAULIC TANK STRAINER....1217
CLEAN THE ENGINE BREATHER....1217
CLEAN, CHECK TURBOCHARGER....1218
CHECK ALTERNATOR, STARTING MOTOR....1218
CHECK ENGINE VALVE CLEARANCE, ADJUST....1218
CHECK VIBRATION DAMPER....1218
EVERY 4000 HOURS MAINTENANCE....1218
PREVIOUS MAINTENANCE....1218
CHECK WATER PUMP....1218
EVERY 5000 HOURS MAINTENANCE....1219
PREVIOUS MAINTENANCE....1219
CHANGE OIL IN HYDRAULIC TANK....1219
SPECIFICATIONS....1221
SPECIFICATIONS....1222
DIMENSIONS....1222
WORKING RANGE....1224
LIFTING CAPACITY....1226
OPTIONS, ATTACHMENTS....1229
GENERAL PRECAUTIONS....1230
SAFETY RELATED PRECAUTIONS....1230
PRECAUTIONS WHEN INSTALLING ATTACHMENTS....1231
HANDLING THE BUCKET WITH HOOK....1232
CHECKING FOR DAMAGE TO BUCKET HOOK....1232
PROHIBITED OPERATIONS....1232
PRECAUTIONS DURING OPERATIONS....1232
COMBINATIONS OF WORK EQUIPMENT FOR PC300LL-7....1233
SELECTION OF TRACK SHOES....1234
CEAM207074 - Hydraulic Excavator PC300-5 (Mighty), PC300LC-5 (Mighty), PC300LC-5K, PC300HD-5 Operation & Maintenance Manual....1237
FOREWORD....1239
CONTENTS....1241
OPERATION....1242
GENERAL LOCATIONS AND SPECIFICATIONS....1242
INSTRUMENTS AND CONTROLS....1244
METHOD OF USING MODE SELECTOR SWITCHES....1284
CHECK BEFORE STARTING....1288
OPERATING YOUR MACHINE....1294
INVERSION AND REPLACEMENT OF BUCKET....1318
HANDLING THE TRAPEZOIDAL BUCKET (EXCEPT PC300, 3OOLC-5 MIGHTY)....1320
HANDLING THE CLAMSHELL BUCKET (EXCEPT PC300, 3OOLC-5 MIGHTY)....1320
SELECTION OF TRACK SHOES (EXCEPT PC300, 3OOLC-5 MIGHTY)....1322
SELECTION OF BUCKET TEETH....1324
TRANSPORTATION....1326
INSTALLATION OF OPTIONAL ELECTRICAL EQUIPMENT....1336
COLD WEATHER OPERATION....1338
MAINTENANCE....1347
PERIODIC MAINTENANCE....1347
PRECAUTIONS WHEN DISASSEMBLING MACHINE....1348
BLEEDING AIR FROM CIRCUIT....1350
PERIODICAL REPLACEMENT OF SAFETY PARTS....1354
MAINTENANCE TABLE....1358
OIL FILLER AND LEVEL GAUGE POSITIONS....1362
EVERY 100 HOURS SERVICE....1364
EVERY 250 HOURS SERVICE....1370
EVERY 500 HOURS SERVICE....1378
EVERY 1000 HOURS SERVICE....1382
EVERY 2000 HOURS SERVICE....1386
EVERY 4000 HOURS SERVICE....1391
WHEN REQUIRED....1392
ADJUSTMENT....1410
TROUBLE SHOOTING GUIDE....1412
SERVICE METER....1422
MACHINE AND ENGINE SERIAL NUMBERS....1424
FUEL, COOLANT AND LUBRICANTS....1426
SAFETY AND OPERATION....1429
CONTENTS....1431
SAFETY HINTS....1432
RADIO....1448
LOCKING CAP....1452
OPERATING THE CAR COOLER....1454
OPERATING THE AIR CONDITIONER (EXCEPT PC300, 3OOLC-5 MIGHTY)....1458
EXCAVATOR’S WORK....1468
HANDLING OF BATTERY....1470
PRECAUTIONS FOR MAINTENANCE....1476
STORAGE....1482
COOLANT AND LUBRICANTS....1484
CEAM3006C1 - Hydraulic Excavator PC300LC-6, PC300HD-6 Operation & Maintenance Manual....1486
1. FORWARD....1489
2. SAFETY INFORMATION....1490
3. INTRODUCTION....1491
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....1492
5. CONTENTS....1493
SAFETY....1497
6. GENERAL PRECAUTIONS....1498
7. PRECAUTIONS DURING OPERATION....1505
7.1 BEFORE STARTING ENGINE....1505
7.2 OPERATING MACHINE....1507
7.3 TRANSPORTATION....1513
7.4 BATTERY....1514
7.5 TOWING....1515
7.6 BUCKET WITH HOOK....1516
8. PRECAUTIONS FOR MAINTENANCE....1518
8.1 BEFORE CARRYING OUT MAINTENANCE....1518
8.2 DURING MAINTENANCE....1521
9. POSITION FOR ATTACHING SAFETY LABLES....1525
OPERATION....1529
10. GENERAL VIEW....1530
10.1 GENERAL VIEW OF MACHINE....1530
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....1531
11. EXPLANATION OF COMPONENTS....1532
11.1 MACHINE MONITOR....1532
11.2 SWITCHES....1543
11.3 CONTROL LEVERS, PEDALS....1547
11.4 CEILING WINDOW....1552
11.5 FRONT WINDOW....1553
11.6 DOOR LOCK....1555
11.7 CAP, COVER WITH LOCK....1556
11.8 HOT/COOL BOX....1557
11.9 LUGGAGE BOX....1557
11.10 ASHTRAY....1557
11.11 HANDLING AIR CONDITIONER....1558
11.12 CAR RADIO....1561
11.13 FUSE....1566
11.14 FUSIBLE LINK....1567
11.15 CONTROLLERS....1567
11.16 TOOL BOX....1567
11.17 GREASE GUN HOLDER....1567
11.18 HANDLING ACCUMULATOR....1568
12. OPERATION....1569
12.1 CHECK BEFORE STARTING....1569
12.2 STARTING ENGINE....1580
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE....1583
12.4 MOVING MACHINE OFF....1589
12.5 STEERING MACHINE....1592
12.6 STOPPING MACHINE....1594
12.7 SWINGING....1595
12.8 OPERATION OF WORK EQUIPMENT....1596
12.9 WORKING MODE SELECTION....1597
12.10 PROHIBITIONS FOR OPERATION....1599
12.11 PRECAUTIONS FOR OPERATION....1601
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS....1602
12.13 HOW TO ESCAPE FROM MUD....1604
12.14 WORKPOSSIBLE USING HYDRAULIC EXCAVATOR....1605
12.15 REPLACEMENT AND INVERSION OF BUCKET....1606
12.16 PARKING MACHINE....1608
12.17 CHECK AFTER FINISHING WORK....1609
12.18 STOPPING ENGINE....1610
12.19 CHECK AFTER STOPPING ENGINE....1611
12.20 LOCKING AND SECURING MACHINE....1611
13. TRANSPORTATION....1612
13.1 LOADING AND UNLOADING MACHINE....1612
13.2 PRECAUTIONS FOR LOADING....1614
13.3 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GUAGE (PC300HD-6)....1615
13.4 PRECAUTIONS FOR TRANSPORTATION....1616
14. COLD WEATHER OPERATION....1617
14.1 PRECAUTIONS FOR LOW TEMPERATURE....1617
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....1619
14.3 AFTER COLD WEATHER....1619
15. LONG-TERM STORAGE....1620
15.1 BEFORE STORAGE....1620
15.2 DURING STORAGE....1621
15.3 AFTER STORAGE....1621
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE....1621
16. TROUBLESHOOTING....1622
16.1 PHENOMENA THAT ARE NOT FAILURES....1622
16.2 METHOD OF TOWING MACHINE....1622
16.3 METHOD FOR USING LIGHT-WEIGHT....1622
16.4 PRECAUTIONS ON PARTICULAR JOB SITES....1623
16.5 IF BATTERY IS DISCHARGED....1623
16.6 OTHER TROUBLE....1627
MAINTENANCE....1632
17. GUIDES TO MAINTENANCE....1633
18. OUTLINES OF SERVICE....1636
18.1 OUTLINE OF OIL, FUEL, COOLANT....1636
18.2 OUTLINE OF ELECTRIC SYSTEM....1639
18.3 OUTLINE OF HYDRAULIC SYSTEM....1639
18.4 OUTLINE OF FUEL SYSTEM....1640
19. WEAR PARTS LIST....1641
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....1643
20.1 PROPER SELECTION OF FUEL. COOLANT AND LUBRICANTS....1643
20.2 ENGINE OIL SPECIFICATIONS....1644
20.3 DIESEL FUEL SPECIFICATIONS....1645
20.4 COOLANT SPECIFICATIONS....1646
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....1651
21.1 INTRODUCTION OF NECESSARY TOOLS....1651
21.2 TORQUE LIST....1652
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1653
23. MAINTENANCE SCHEDULE CHART....1655
23.1 MAINTENANCE SCHEDULE CHART....1655
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER....1658
24. SERVICE PROCEDURE....1659
24.1 INITIAL 250 HOURS SERVICE....1659
24.2 WHEN REQUIRED....1660
24.3 CHECK BEFORE STARTING....1682
24.4 EVERY 50 HOURS SERVICE....1686
24.5 EVERY 100 HOURS SERVICE....1688
24.6 EVERY 250 HOURS SERVICE....1690
24.7 EVERY 500 HOURS SERVICE....1698
24.8 EVERY 1000 HOURS SERVICE....1704
24.9 EVERY 2000 HOURS SERVICE....1707
24.10 EVERY 4000 HOURS SERVICE....1714
SPECIFICATIONS....1715
25. SPECIFICATIONS....1716
OPTIONS, ATTACHMENTS....1721
26. GENERAL PRECAUTIONS....1722
26.1 PRECAUTIONS RELATED TO SAFETY....1722
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....1723
27. HANDLING BUCKET WITH HOOK....1724
27.1 CHECK FOR DAMAGE TO BUCKET WITH....1724
27.2 PROHIBITED OPERATIONS....1724
27.3 PRECAUTIONS DURING OPERATIONS....1724
28. USING SEAT BELT....1725
28.1 SEAT BELT....1725
28.1.1 FASTEN THE BELT AND REMOVE IT....1725
28.1.2 ADJUST THE BELT LENGTH....1726
29. HANDLING CAB HEATER....1727
29.1 EXPLANATION OF COMPONENTS....1727
29.2 PREPARING CAB HEATER....1728
30. HANDLING LARGE CAPACITY CAB HEATER....1729
30.1 EXPLANATION OF COMPONENTS....1729
30.2 PREPARING CAB HEATER....1730
31. MACHINES READY FOR ATTACHMENTS....1731
31.1 EXPLANATION OF COMPONENTS....1731
31.2 HYDRAULIC CIRCUIT....1733
31.3 PROCEDURE FOR REMOVAL AND INSTALLATION OF ATTACHMENT....1735
31.4 OPERATION....1737
31.5 LONG-TERM STORAGE....1738
31.6 SPECIFICATIONS....1738
32. INTRODUCTION OF ATTACHMENTS....1739
32.1 SPECIFICATION, USE PC300LC-6....1739
32.2 SPECIFICATION, USE PC300HD-6....1740
32.3 ATTACHMENT INSTALLATION COMBINATION TABLE PC300LC-6 AVANCE....1741
32.4 ATTACHMENT INSTALLATION COMBINATION TABLE PC300HD-6 AVANCE....1742
32.5 SELECTION OF TRACK SHOES....1743
32.6 BUCKET SELECTION....1744
32.7 HANDLING TRAPEZOIDAL BUCKET....1745
33. EXTENDING MACHINE SERVICE LIFE....1746
33.1 HYDRAULIC BREAKER....1746
33.2 CRUSHER....1749
33.3 GRAPPLE....1750
33.4 BUCKET WITH THUMB GRAPPLE....1751
33.5 ROTATING GRAPPLE....1752
33.6 SHEAR....1753
33.7 HYDRAULIC PILE DRIVER....1754
33.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE....1755
CEBM009104 - Hydraulic Excavator PC300LC-7L, PC300HD-7L Shop Manual....1757
COVER....1757
CONTENTS....1758
FOREWORD....1765
SAFETY....1765
SAFETY NOTICE....1765
IMPORTANT SAFETY NOTICE....1765
GENERAL PRECAUTIONS....1765
PREPARATIONS FOR WORK....1765
PRECAUTIONS DURING WORK....1765
GENERAL....1767
HOW TO READ THE SHOP MANUAL....1768
VOLUMES....1768
DISTRIBUTION AND UPDATING....1768
FILING METHOD....1768
REVISED EDITION MARK....1768
REVISIONS....1768
SYMBOLS....1768
HOISTING INSTRUCTIONS....1769
HOISTING....1769
WIRE ROPES....1769
COATING MATERIALS....1770
STANDARD TIGHTENING TORQUE....1772
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS....1772
TIGHTENING TORQUE OF HOSE NUTS....1773
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....1773
TIGHTENING TORQUE FOR FLARED NUTS....1773
ELECTRIC WIRE CODE....1774
CLASSIFICATION BY THICKNESS....1774
CLASSIFICATION BY COLOR AND CODE....1774
CONVERSION TABLES....1775
METHOD OF USING THE CONVERSION TABLE....1775
01 GENERAL....1781
SPECIFICATION DIMENSION DRAWINGS....1782
DIMENSIONS....1782
WORKING RANGES....1782
DIMENSIONS....1783
WORKING RANGES....1783
SPECIFICATIONS....1784
WEIGHT TABLE....1786
FUEL, COOLANT, AND LUBRICANTS....1788
PC300LC-7L....1788
PC300HD-7L....1789
10 STRUCTURE AND FUNCTION....1791
ENGINE RELATED PARTS....1793
RADIATOR • OIL COOLER • AFTERCOOLER....1794
FINAL DRIVE....1796
PC300LC-7L....1796
PC300HD-7L....1798
SPROCKET....1799
REAL DIMENSION OF SPROCKET TOOTH SHAPE....1800
SWING MACHINERY....1802
SWING CIRCLE....1804
TRACK FRAME • RECOIL SPRING....1806
PC300LC-7L....1806
PC300HD-7L....1808
IDLER....1810
CARRIER ROLLER....1812
TRACK ROLLER....1813
TRACK SHOE....1814
TRIPLE GROUSER SHOE....1817
HYDRAULIC EQUIPMENT LAYOUT DRAWING....1818
HYDRAULIC TANK....1820
HYDRAULIC PUMP....1822
HPV125 + 125....1822
LS VALVE....1827
PC VALVE....1827
LS(PC)-EPC VALVE....1840
VARIABLE VOLUME VALVE....1843
CONTROL VALVE....1846
MAIN RELIEF VALVE....1860
VARIABLE PRESSURE COMPENSATION VALVE....1861
CLSS....1862
SELF PRESSURE REDUCING VALVE....1865
SWING MOTOR....1869
RELIEF VALVE PORTION....1872
SWING LOCK....1873
REVERSE PREVENTION VALVE....1874
CENTER SWIVEL JOINT....1877
TRAVEL MOTOR....1879
PC300LC-7L....1879
MOTOR OPERATION....1882
PARKING BRAKE OPERATION....1884
PC300HD-7L....1885
MOTOR OPERATION....1887
PARKING BRAKE OPERATION....1889
BRAKE VALVE OPERATION....1890
TRAVEL JUNCTION VALVE....1895
TRAVEL PPC SHUTTLE VALVE....1898
VALVE CONTROL....1902
WORK EQUIPMENT • SWING PPC VALVE....1903
TRAVEL PPC VALVE....1909
SERVICE VALVE....1918
SOLENOID VALVE....1921
PPC ACCUMULATOR....1923
RETURN OIL FILTER....1924
FOR BREAKER....1924
BOOM HYDRAULIC DRIFT PREVENTION VALVE....1926
QUICK RETURN VALVE....1932
LIFT CHECK VALVE....1934
ATTACHMENT CIRCUIT SELECTOR VALVE....1935
HYDRAULIC CYLINDER....1938
BOOM CYLINDER....1938
ARM CYLINDER....1938
BUCKET CYLINDER....1939
WORK EQUIPMENT....1940
DIMENSION OF ARM....1942
DIMENSION OF BUCKET....1944
AIR CONDITIONER....1946
PIPING....1946
ENGINE CONTROL....1947
FUEL CONTROL DIAL....1949
GOVERNOR MOTOR....1950
ENGINE THROTTLE AND PUMP CONTROLLER....1952
INPUT AND OUTPUT SIGNALS....1953
ELECTRONIC CONTROL SYSTEM....1955
TOTAL SYSTEM DIAGRAM....1956
MULTI MONITOR SYSTEM....1979
MONITOR PANEL....1980
MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION....1982
MAINTENANCE FUNCTION....1992
SENSORS....1997
ENGINE OIL LEVEL SENSOR....1998
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)....1998
COOLANT TEMPERATURE SENSOR....1998
HYDRAULIC OIL TEMPERATURE SENSOR....1998
FUEL LEVEL SENSOR....1999
AIR CLEANER CLOGGING SENSOR....1999
20 TESTING, ADJUSTING AND TROUBLESHOOTING....2001
STANDARD VALUE TABLES....2003
ENGINE RELATED....2003
CHASSIS RELATED....2004
TESTING AND ADJUSTING....2013
SERVICE TOOLS....2015
ENGINE....2016
AIR BOOST PRESSURE....2016
AIR COMPRESSOR BELT TENSION....2016
BLOW-BY PRESSURE....2016
COMPRESSION PRESSURE....2016
ENGINE OIL PRESSURE....2016
ENGINE RPM....2016
ENGINE SPEED SENSOR....2016
EXHAUST GAS COLOR....2016
FUEL INJECTION TIMING....2016
VALVE CLEARANCE....2016
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE....2017
SWING CIRCLE BEARINGS....2018
TRACK SHOE TENSION....2019
SPROCKET....2019
OIL PRESSURE....2020
WORK EQUIPMENT, SWING AND TRAVEL....2020
CONTROL CIRCUIT....2025
PUMP PC CONTROL CIRCUIT....2026
PUMP LS CONTROL CIRCUIT....2029
SOLENOID VALVE OUTPUT....2034
PPC VALVE OUTPUT....2037
WORK EQUIPMENT AND SWING PPC VALVE....2038
WORK EQUIPMENT, HYDRAULIC DRIFT LOCATIONS....2039
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT....2039
BOOM AND BUCKET CYLINDERS....2039
BOOM LOCK VALVE....2040
ARM CYLINDER....2040
PPC VALVE....2041
OIL LEAKAGE AMOUNT....2042
BOOM CYLINDER....2042
ARM CYLINDER....2042
BUCKET CYLINDER....2043
SWING MOTOR....2043
TRAVEL MOTOR....2044
AIR BLEEDING OF VARIOUS PARTS....2045
DIODE INSPECTION PROCEDURES....2047
MULTI-MONITOR PANEL....2049
MONITOR PANEL FUNCTIONS....2050
OPERATOR’S MENU AND DISPLAY (OUTLINE)....2051
TABLE FOR SERVICE AND FAILURE CODE NOS....2056
SERVICE MENU....2058
WAY OF SWITCHING TO SERVICE MENU....2058
TABLE FOR MONITORING ITEMS....2061
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARTIONS....2075
PC300HD-7L Serial No. A85049 and UP....2076
PC300LC-7L Serial No. A86675 and UP....2076
PM TUNE SERVICE....2078
TROUBLESHOOTING GENERAL....2083
TROUBLESHOOTING POINTS TO REMEMBER....2085
SEQUENCE OF EVENTS IN TROUBLESHOOTING....2087
CARRYING OUT MAINTENANCE POINTS TO REMEMBER....2088
CHECKS BEFORE TROUBLESHOOTING....2096
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING....2097
CONNECTOR TABLE....2101
CONNECTOR LOCATION DIAGRAM....2112
PC300HD-7L Serial No. A85049 and UP....2120
PC300LC-7L Serial No. A86675 and UP....2120
CONNECTOR LOCATION DIAGRAM....2125
ELECTRICAL DIAGRAM FOLDOUTS....2131
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....2132
TROUBLESHOOTING ELECTRICAL SYSTEM (E-MODE)....2159
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....2163
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF....2163
USER CODE MEMORY RETENTION FUNCTION....2163
ERROR, FAILURE CODES AND POSSIBLE CAUSES....2164
CONNECTION TABLE OF FUSE BOX....2168
INFORMATION CONTAINED IN TESTING PROCEDURES....2170
(E101)....2172
ABNORMAL DATA IN ERROR HISTORY....2172
(E112)....2176
SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION....2176
(E113)....2178
SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION....2178
(E114)....2180
SHORT OR OPEN IN WINDOW WASHER SYSTEM....2180
(E115)....2182
ABNORMAL WINDSHIELD WIPER MOTION....2182
(E116)....2184
ABNORMALITY IN PARKING WIPER ARM....2184
(E201)....2186
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID....2186
(E203)....2190
SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM....2190
(E204)....2194
SHORT IN MERGE/DIVIDE SOLENOID....2194
(E205)....2198
SHORT IN 2 STAGE RELIEF SOLENOID....2198
(E206)....2202
SHORT IN TRAVEL SPEED SHIFT SOLENOID....2202
(E211)....2206
OPEN IN TRAVEL INTERLOCKING SOLENOID....2206
(E213)....2210
OPEN IN SWING PARKING BRAKE SOLENOID....2210
(E214)....2214
OPEN OF MERGE/DIVIDE SOLENOID....2214
(E215)....2218
OPEN IN 2 STAGE RELIEF SOLENOID....2218
(E216)....2222
OPEN IN TRAVEL SPEED SOLENOID....2222
(E217)....2226
ABNORMAL INPUT FOR MODEL CODE....2226
(E218)....2228
OPEN IN S-NET SIGNAL....2228
(E222)....2230
SHORT IN LS-EPC SOLENOID....2230
(E223)....2232
OPEN IN LS-EPC SOLENOID SYSTEM....2232
(E224)....2234
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL....2234
(E225)....2236
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL....2236
(E226)....2238
ABNORMAL PRESSURE SENSOR POWER SUPPLY....2238
(E227)....2240
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER....2240
(E228)....2242
SHORT IN ATTACHMENT RETURN SWITCHING RELAY....2242
(E232)....2244
SHORT IN PC-EPC SOLENOID....2244
(E233)....2246
OPEN IN PC-EPC SOLENOID SYSTEM....2246
(E238)....2248
OPEN IN ATTACHMENT RETURN SWITCH RELAY....2248
(E245)....2250
SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM....2250
(E246)....2252
OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM....2252
(E256)....2254
INCORRECT NON-VOLATILE MEMORY DATA....2254
(E304)....2258
SHORT IN ENGINE STOP SOLENOID SYSTEM....2258
(E314)....2262
OPEN IN ENGINE STOP SOLENOID SYSTEM....2262
(E306)....2264
ABNORMAL GOVERNOR POTENTIOMETER SIGNALS....2264
(E308)....2266
ABNORMAL FUEL DIAL SIGNALS....2266
(E315)....2268
SHORT IN BATTERY RELAY SYSTEM....2268
(E316)....2270
STEP OUT IN GOVERNOR MOTOR....2270
(E317)....2272
OPEN IN GOVERNOR MOTOR PHASE “A” AND “B”....2272
(E318)....2274
SHORT IN GOVERNOR MOTOR PHASE “A” AND “B”....2274
(E501)....2276
MODEL SELECTION FUNCTION NOT PROVIDED....2276
(E502)....2277
MODEL SELECTING SIGNAL FAULT....2277
(AA10NX)....2278
AIR CLEANER CLOG INDICATOR FAILURE....2278
(AB00KE)....2280
LOW CHARGING VOLTAGE INDICATED....2280
(B@BAZG)....2282
ABNORMAL ENGINE OIL PRESSURE....2282
(B@BAZK)....2284
ABNORMAL ENGINE OIL LEVEL....2284
(B@BCNS)....2286
ENGINE COOLANT INDICATING OVERHEAT CONDITION....2286
(B@BCZK)....2288
ABNORMAL COOLANT LEVEL INDICATION....2288
(B@HANS)....2290
HYDRAULIC OIL OVERHEAT INDICATION....2290
TROUBLESHOOTING MONITOR ELECTRICAL SYSTEM (E-MODE)....2293
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....2295
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF....2295
USER CODE MEMORY RETENTION FUNCTION....2295
INFORMATION CONTAINED IN TESTING PROCEDURES....2149
(E-1)....2298
ENGINE WILL NOT CRANK....2298
(E-2)....2300
ENGINE STOPS WHILE IN OPERATION....2300
(E-3)....2302
ENGINE SPEED IRREGULAR, OR HUNTING....2302
(E-4)....2304
ENGINE DOES NOT SHUT DOWN....2304
(E-5)....2306
AUTO DECELERATOR DOES NOT WORK....2306
(E-6)....2307
AUTO ENGINE WARM UP DEVICE DOES NOT WORK....2307
(E-7)....2308
COLD START PREHEATER DOES NOT WORK....2308
(E-8)....2310
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE....2310
(E-9)....2312
ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE....2312
(E-10)....2314
NO DISPLAY ON MONITOR PANEL....2314
(E-11)....2316
PART OF DISPLAY ON MONITOR PANEL IS MISSING....2316
(E-12)....2317
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL....2317
(E-13)....2318
FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL....2318
(E-14)....2320
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY....2320
(E-15)....2322
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY....2322
(E-16)....2324
FUEL GAUGE DOES NOT DISPLAY CORRECTLY....2324
(E-17)....2326
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY....2326
(E-18)....2328
WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS....2328
(E-19)....2330
WINDSHIELD WIPER DOES NOT WORK....2330
(E-20)....2332
ALARM BUZZER CANNOT BE CANCELLED....2332
(E-21)....2334
BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR....2334
(E-22)....2336
BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR....2336
(E-23)....2338
ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR....2338
(E-24)....2340
ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR....2340
(E-25)....2342
BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR....2342
(E-26)....2344
BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR....2344
(E-27)....2346
SWING NOT CORRECTLY DISPLAYED ON MONITOR....2346
(E-28)....2348
TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR....2348
(E-29)....2350
TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR....2350
(E-30)....2352
SERVICE NOT CORRECTLY DISPLAYED ON MONITOR....2352
(E-31)....2354
AIR CONDITIONER SYSTEM DOES NOT WORK....2354
(E-32)....2372
TRAVEL ALARM DOES NOT SOUND....2372
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSEM (H-MODE)....2375
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS....2377
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE....2379
(H-1)....2380
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW....2380
(H-2)....2381
ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS....2381
(H-3)....2382
NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT....2382
(H-4)....2382
ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP....2382
(H-5)....2383
AUTO-DECELERATOR DOES NOT WORK....2383
(H-6)....2383
FINE CONTROL MODE DOES NOT FUNCTION....2383
(H-7)....2025
BOOM MOVES SLOWLY OR LACKS POWER....2384
(H-8)....2385
ARM MOVES SLOWLY OR LACKS POWER....2385
(H-9)....2386
BUCKET MOVES SLOWLY OR LACKS POWER....2386
(H-10)....2387
WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION....2387
(H-11)....2388
WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT....2388
(H-12)....2389
WORK EQUIPMENT HAS EXCESSIVE LAG TIME....2389
(H-13)....2390
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT....2390
(H-14)....2390
ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE....2390
(H-15)....2390
IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY....2390
(H-16)....2391
IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY....2391
(H-17)....2391
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY....2391
(H-18)....2392
MACHINE SWERVES WHEN TRAVELING....2392
(H-19)....2352
MACHINE TRAVELS SLOWLY....2393
(H-20)....0
MACHINE CANNOT BE STEERED EASILY OR LACKS POWER....2394
(H-21)....2395
TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING....2395
(H-22)....2395
TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY)....2395
(H-23)....2396
MACHINE DOES NOT SWING....2396
(H-24)....2397
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW....2397
(H-25)....1757
EXCESSIVE OVERRUN WHEN STOPPING SWING....2398
(H-26)....2399
THERE IS A SUDDEN SHOCK WHEN STOPPING SWING....2399
(H-27)....2399
ABNORMAL NOISE CAUSED WHEN STOPPING SWING....2399
(H-28)....2400
SWING NATURAL DRIFT IS EXCESSIVE....2400
30 DISASSEMBLY AND ASSEMBLY....2401
METHOD OF USING MANUAL....2405
PRECAUTIONS DURING OPERATION....2406
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK....2019
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK....2407
PRECAUTIONS WHEN COMPLETING THE OPERATIONS....2408
OTHER PRECAUTIONS....2408
SPECIAL TOOL LIST....2409
SKETCHES OF SPECIAL TOOLS....2412
ENGINE....2413
ALTERNATOR....2413
CYLINDER HEAD....2413
ENGINE FRONT SEAL....2413
ENGINE OIL COOLER....2413
ENGINE REAR SEAL....2413
FUEL INJECTION PUMP....2413
NOZZLE HOLDER....2413
STARTING MOTOR....2413
THERMOSTAT....2413
TURBOCHARGER....2413
WATER PUMP....2413
RADIATOR....2414
REMOVAL....2414
INSTALLATION....2415
HYDRAULIC OIL COOLER....2416
REMOVAL....2416
INSTALLATION....2417
ENGINE AND HYDRAULIC PUMPS....2418
REMOVAL....2032
INSTALLATION....2422
FINAL DRIVE....2423
REMOVAL....2423
INSTALLATION....2423
DISASSEMBLY....2424
ASSEMBLY....2428
SWING MOTOR AND SWING MACHINERY....2435
REMOVAL....2015
INSTALLATION....2436
DISASSEMBLY....2437
ASSEMBLY....2440
CARRIER ROLLER....2445
ASSEMBLY....2445
TRACK ROLLER....2446
ASSEMBLY....2446
IDLER....2447
DISASSEMBLY....2447
ASSEMBLY....2448
RECOIL SPRING....2451
DISASSEMBLY....2451
ASSEMBLY....2452
SPROCKET....2454
REMOVAL....2454
INSTALLATION....2454
TRACK SHOE....2455
EXPANSION OF TRACK SHOE....2455
ASSEMBLY....2456
SWING CIRCLE....2457
REMOVAL....2457
INSTALLATION....2457
REVOLVING FRAME....2458
REMOVAL....2458
INSTALLATION....2460
CENTER SWIVEL JOINT....2461
REMOVAL....2461
INSTALLATION....2462
DISASSEMBLY....2463
ASSEMBLY....2463
HYDRAULIC TANK....2464
REMOVAL....2464
INSTALLATION....2465
CONTROL VALVE....2018
REMOVAL....2466
INSTALLATION....2468
PROCEDURES FOR REPLACING PRESSURE COMPENSATION VALVE SEAL....2469
ASSEMBLY....2470
HYDRAULIC PUMP....2471
REMOVAL....2471
INSTALLATION....2473
INPUT SHAFT OIL SEAL....2474
REMOVAL....2474
INSTALLATION....2474
WORK EQUIPMENT PPC VALVE....2475
ASSEMBLY....2475
TRAVEL PPC VALVE....2476
ASSEMBLY....2476
HYDRAULIC CYLINDER....2477
DISASSEMBLY....2477
ASSEMBLY....2479
WORK EQUIPMENT....2484
REMOVAL....2484
INSTALLATION....2486
AIR CONDITIONER....2487
REMOVAL....2487
INSTALLATION....2490
COUNTERWEIGHT....2491
REMOVAL....2491
INSTALLATION....2062
OPERATOR’S CAB....2492
REMOVAL....2062
INSTALLATION....2494
MONITOR....2495
REMOVAL....2495
INSTALLATION....2495
GOVERNOR PUMP CONTROLLER....2496
REMOVAL....2496
INSTALLATION....2496
90 OTHERS....2497
ELECTRICAL....2499
ELECTRICAL (PC300HD-7L SERIAL NO. A85001 THROUGH A85047 AND PC300LC-7L SERIAL NO. A85001 THROUGH A86673)....2499
ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 3) FOLDOUT 1....2499
ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 3) FOLDOUT 2....2501
ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 3) FOLDOUT 3....2503
ELECTRICAL DIAGRAM 2/4 (SHEET 1 OF 1) FOLDOUT 4....2505
ELECTRICAL DIAGRAM 3/4 (SHEET 1 OF 2) FOLDOUT 5....2507
ELECTRICAL DIAGRAM 3/4 (SHEET 2 OF 2) FOLDOUT 6....2509
ELECTRICAL DIAGRAM 4/4 (SHEET 1 OF 2) FOLDOUT 7....2511
ELECTRICAL DIAGRAM 4/4 (SHEET 2 OF 2) FOLDOUT 8....2513
ELECTRICAL (PC300HD-7L SERIAL NO. A85049 AND UP/PC300LC-7L SERIAL NO. A86675 AND UP)....2515
ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 9) FOLDOUT 1....2515
ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 9) FOLDOUT 2....2517
ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 9) FOLDOUT 3....2519
ELECTRICAL DIAGRAM 2/4 (SHEET 4 OF 9) FOLDOUT 1....2521
ELECTRICAL DIAGRAM 3/4 (SHEET 5 OF 9) FOLDOUT 2....2523
ELECTRICAL DIAGRAM 3/4 (SHEET 6 OF 9) FOLDOUT 3....2525
ELECTRICAL DIAGRAM 4/4 (SHEET 7 OF 9) FOLDOUT 1....2527
ELECTRICAL DIAGRAM 4/4 (SHEET 8 OF 9) FOLDOUT 2....2529
ELECTRICAL DIAGRAM 4/4 (SHEET 9 OF 9) FOLDOUT 3....2531
HYDRAULIC ....2533
HYDRAULIC DIAGRAM (SHEET 1 OF 3) FOLDOUT 9....2533
HYDRAULIC DIAGRAM (SHEET 2 OF 3) FOLDOUT 10....2535
HYDRAULIC DIAGRAM (SHEET 3 OF 3) FOLDOUT 11....2537
CEBM012100 - Hydraulic Excavator GALEO PC300LL-7L Shop Manual....2539
COVER....2539
CONTENTS....2540
SAFETY....2543
SAFETY NOTICE....2543
FOREWARD....2545
GENERAL....2545
HOW TO READ THE SHOP MANUAL....2546
HOISTING INSTRUCTIONS....2547
COATING MATERIALS....2548
STANDARD TIGHTENING TORQUE....2550
ELECTRIC WIRE CODE....2555
CONVERSION TABLES....2556
UNITS....2561
01 GENERAL....2563
DIMENSION DRAWINGS....2564
DIMENSIONS....2564
WORKING RANGES....2566
SPECIFICATIONS....2568
WEIGHT TABLE....2571
POWERED CAB RISER TILT UNIT TARGETS....2573
FUEL COOLANT AND LUBRICANTS....2574
PC300LL-7L....2574
10 STRUCTURE AND FUNCTION....2575
ENGINE RELATED PARTS....2577
RADIATOR . OIL COOLER . AFTERCOOLER....2578
FINAL DRIVE SYSTEM....2580
PC300LL-7L....2580
SWING MACHINERY....2583
SWING CIRCLE....2586
TRACK FRAME . RECOIL SPRING....2588
PC300LL-7L....2588
IDLER....2589
TRACK ROLLER....2591
TRACK SHOE....2592
TRIPLE GROUSER SHOE....2594
HYDRAULIC EQUIPMENT....2595
HYDRAULIC TANK....2597
HYDRAULIC PUMP....2598
HPV125 + 125....2598
LS VALVE....2603
PC VALVE....2603
LS(PC)-EPC VALVE....2615
VARIABLE VOLUME VALVE....2618
CONTROL VALVE....2620
MAIN RELIEF VALVE....2631
VARIABLE PRESSURE COMPENSATION VALVE....2632
CLSS....2633
SELF PRESSURE REDUCING VALVE....2636
SWING MOTOR....2639
SUCTION-SAFETY VALVE....2642
SWING BRAKE....2643
CENTER SWIVEL JOINT....2644
PC300LL-7L....2645
MOTOR OPERATION....2647
PARKING BRAKE OPERATION....2649
BRAKE VALVE OPERATION....2650
TRAVEL JUNCTION VALVE....2654
TRAVEL PPC SHUTTLE VALVE....2656
VALVE CONTROL....2660
WORK EQUIPMENT . SWING PPC VALVE....2661
TRAVEL PPC VALVE....2665
ATTACHMENT SOLENOID VALVE....2674
PPC ACCUMULATOR....2676
BOOM HYDRAULIC DRIFT PREVENTION VALVE....2677
QUICK RETURN VALVE....2683
LIFT CHECK VALVE....2685
HYDRAULIC CYLINDER....2686
BOOM CYLINDER....2686
ARM CYLINDER....2686
BUCKET CYLINDER....2687
WORK EQUIPMENT....2688
DIMENSION OF ARM....2690
DIMENSION OF BUCKET....2692
AIR CONDITIONER....2694
PIPING....2694
ENGINE CONTROL....2695
FUEL CONTROL DIAL....2697
GOVERNOR MOTOR....2698
ENGINE THROTTLE AND PUMP CONTROLLER....2699
INPUT AND OUTPUT SIGNALS....2700
ELECTRONIC CONTROL SYSTEM....2701
TOTAL SYSTEM DIAGRAM....2702
MULTI MONITOR SYSTEM....2725
MONITOR PANEL....2726
MONITOR CONTROL, DISPLAY PORTION /MONITOR PORTION....2728
MAINTENANCE FUNCTION....2739
SENSORS....2744
ENGINE OIL LEVEL SENSOR....2744
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)....2744
COOLANT TEMPERATURE SENSOR....2745
HYDRAULIC OIL TEMPERATURE SENSOR....2745
FUEL LEVEL SENSOR....2746
AIR CLEANER CLOGGING SENSOR....2746
CAB RISER AND RELATED PARTS....2747
POWER CONTROL....2748
STRESS TARGETS FOR CAB RISER KIT....2749
CAB RISER HYDRAULIC SYSTEM....2750
20 TESTING, ADJUSTING AND TROUBLESHOOTING....2751
STANDARD VALUE TABLES....2753
ENGINE RELATED....2753
CHASSIS RELATED....2754
SERVICE TOOLS....2762
ENGINE....2762
AIR BOOST PRESSURE....2762
AIR COMPRESSOR BELT TENSION....2762
BLOW-BY PRESSURE....2762
COMPRESSION PRESSURE....2762
ENGINE OIL PRESSURE....2762
ENGINE RPM....2762
ENGINE SPEED SENSOR....2763
EXHAUST GAS COLOR....2763
FUEL INJECTION TIMING....2763
VALVE CLEARANCE....2763
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE....2764
SWING CIRCLE BEARINGS....2764
TRACK SHOE TENSION....2765
SPROCKET....2766
OIL PRESSURE....2766
WORK EQUIPMENT, SWING AND TRAVEL....2766
CONTROL CIRCUIT....2771
PUMP PC CONTROL CIRCUIT....2772
PUMP LS CONTROL CIRCUIT....2775
ATTACHMENT SOLENOID VALVE OUTPUT....2779
ATTACHMENT PPC VALVE OUTPUT....2782
WORK EQUIPMENT AND SWING PPC VALVE....2783
WORK EQUIPMENT, HYDRAULIC DRIFT LOCATIONS....2783
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT....2784
BOOM AND BUCKET CYLINDERS....2784
BOOM LOCK VALVE....2784
ARM CYLINDER....2785
PPC VALVE....2785
OIL LEAKAGE AMOUNT....2787
BOOM CYLINDER....2787
ARM CYLINDER....2787
BUCKET CYLINDER....2788
SWING MOTOR....2788
TRAVEL MOTOR....2788
AIR BLEEDING OF VARIOUS PARTS....2789
DIODE INSPECTION PROCEDURES....2791
MULTI-MONITOR PANEL....2792
MONITOR PANEL FUNCTIONS....2793
OPERATOR’S MENU AND DISPLAY (OUTLINE)....2794
TABLE FOR SERVICE AND FAILURE CODE NOS....2799
SERVICE MENU....2801
WAY OF SWITCHING TO SERVICE MENU....2801
TABLE FOR MONITORING ITEMS....2804
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARTIONS....2816
PM TUNE SERVICE....2817
TROUBLESHOOTING (GENERAL)....2821
POINTS TO REMEMBER WHEN TROUBLESHOOTING....2822
SEQUENCE OF EVENTS IN TROUBLESHOOTING....2824
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....2825
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT....2825
HANDLING CONTROL BOX....2830
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS....2831
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT....2832
CHECKS BEFORE TROUBLESHOOTING....2834
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS....2835
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO....2836
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....2839
T-ADAPTER TABLE....2863
TROUBLESHOOTING ELECTRICAL SYSTEM (E MODE)....2867
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....2869
ABNORMALITY RETURNS TO NORMAL BY ITSELF....2869
USER CODE MEMORY RETENTION FUNCTION....2869
INFORMATION CONTAINED IN TESTING PROCEDURES....2870
(E101)....2872
ABNORMAL DATA IN ERROR HISTORY....2872
(E112)....2874
SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION....2874
(E113)....2876
SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION....2876
(E114)....2878
SHORT OR OPEN IN WINDOW WASHER SYSTEM....2878
(E115)....2880
ABNORMAL WINDSHIELD WIPER MOTION....2880
(E116)....2882
ABNORMALITY IN PARKING WIPER ARM....2882
(E201)....2884
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID....2884
(E203)....2886
SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM....2886
(E204)....2888
SHORT IN MERGE/DIVIDE SOLENOID....2888
(E205)....2890
SHORT IN 2 STAGE RELIEF SOLENOID....2890
(E206)....2892
SHORT IN TRAVEL SPEED SHIFT SOLENOID....2892
(E211)....2894
OPEN IN TRAVEL INTERLOCKING SOLENOID....2894
(E213)....2896
OPEN IN SWING PARKING BRAKE SOLENOID....2896
(E214)....2898
OPEN OF MERGE/DIVIDE SOLENOID....2898
(E215)....2900
OPEN IN 2 STAGE RELIEF SOLENOID....2900
(E216)....2902
OPEN IN TRAVEL SPEED SOLENOID....2902
(E217)....2904
ABNORMAL INPUT FOR MODEL CODE....2904
(E218)....2906
OPEN IN S-NET SIGNAL....2906
(E222)....2908
SHORT IN LS-EPC SOLENOID....2908
(E223)....2910
OPEN IN LS-EPC SOLENOID SYSTEM....2910
(E224)....2912
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL....2912
(E225)....2914
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL....2914
(E226)....2916
ABNORMAL PRESSURE SENSOR POWER SUPPLY....2916
(E227)....2918
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER....2918
(E228)....2920
SHORT IN ATTACHMENT RETURN SWITCHING RELAY....2920
(NO CODE)....2922
SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM....2922
(NO CODE)....2925
OPEN IN CAB TILT SYSTEM....2925
(E232)....2927
SHORT IN PC-EPC SOLENOID....2927
(E233)....2929
OPEN IN PC-EPC SOLENOID SYSTEM....2929
(E238)....2931
OPEN IN ATTACHMENT RETURN SWITCH RELAY....2931
(E245)....2933
SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM....2933
(E246)....2935
OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM....2935
(E256)....2937
INCORRECT NON-VOLATILE MEMORY DATA....2937
(E304)....2939
SHORT IN ENGINE STOP SOLENOID SYSTEM....2939
(E314)....2941
OPEN IN ENGINE STOP SOLENOID SYSTEM....2941
(E306)....2943
ABNORMAL GOVERNOR POTENTIOMETER SIGNALS....2943
(E308)....2945
ABNORMAL FUEL DIAL SIGNALS....2945
(E315)....2947
SHORT IN BATTERY RELAY SYSTEM....2947
(E316)....2949
STEP OUT IN GOVERNOR MOTOR....2949
(E317)....2951
OPEN IN GOVERNOR MOTOR PHASE “A” AND “B”....2951
(E318)....2953
SHORT IN GOVERNOR MOTOR PHASE “A” AND “B”....2953
(E501)....2955
MODEL SELECTION FUNCTION NOT PROVIDED....2955
(E502)....2956
MODEL SELECTING SIGNAL FAULT....2956
(AA10NX)....2957
AIR CLEANER CLOG INDICATOR FAILURE....2957
(AB00KE)....2958
LOW CHARGING VOLTAGE INDICATED....2958
(B@BAZG)....2960
ABNORMAL ENGINE OIL PRESSURE....2960
(B@BAZK)....2961
ABNORMAL ENGINE OIL LEVEL....2961
(B@BCNS)....2962
ENGINE COOLANT INDICATING OVERHEAT CONDITION....2962
(B@BCZK)....2963
ABNORMAL COOLANT LEVEL INDICATION....2963
(B@HANS)....2964
HYDRAULIC OIL OVERHEAT INDICATION....2964
TROUBLESHOOTING MONITOR ELECTRICAL SYSTEM (E MODE)....2965
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....2966
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF....2966
USER CODE MEMORY RETENTION FUNCTION....2966
INFORMATION CONTAINED IN TESTING PROCEDURES....2967
(E-1)....2969
ENGINE WILL NOT CRANK....2969
(E-2)....2971
ENGINE STOPS WHILE IN OPERATION....2971
(E-3)....2973
ENGINE SPEED IRREGULAR, OR HUNTING....2973
(E-4)....2975
ENGINE DOES NOT SHUT DOWN....2975
(E-5)....2977
AUTO DECELERATOR DOES NOT WORK....2977
(E-6)....2978
AUTO ENGINE WARM UP DEVICE DOES NOT WORK....2978
(E-7)....2979
COLD START PREHEATER DOES NOT WORK....2979
(E-8)....2981
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE....2981
(E-9)....2983
ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE....2983
(E-10)....2985
NO DISPLAY ON MONITOR PANEL....2985
(E-11)....2987
PART OF DISPLAY ON MONITOR PANEL IS MISSING....2987
(E-12)....2988
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL....2988
(E-13)....2989
FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL....2989
(E-14)....2991
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY....2991
(E-15)....2993
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY....2993
(E-16)....2995
FUEL GAUGE DOES NOT DISPLAY CORRECTLY....2995
(E-17)....2997
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY....2997
(E-18)....2999
WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS....2999
(E-19)....3001
WINDSHIELD WIPER DOES NOT WORK....3001
(E-20)....3003
ALARM BUZZER CANNOT BE CANCELLED....3003
(E-21)....3005
BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR....3005
(E-22)....3007
BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR....3007
(E-23)....3009
ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR....3009
(E-24)....3011
ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR....3011
(E-25)....3013
BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR....3013
(E-26)....3015
BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR....3015
(E-27)....3017
SWING NOT CORRECTLY DISPLAYED ON MONITOR....3017
(E-28)....3019
TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR....3019
(E-29)....3021
TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR....3021
(E-30)....3023
SERVICE NOT CORRECTLY DISPLAYED ON MONITOR....3023
(E-31)....3025
AIR CONDITIONER SYSTEM DOES NOT WORK....3025
(E-32)....3029
TRAVEL ALARM DOES NOT SOUND....3029
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H MODE)....3033
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS....3035
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE....3038
(H-1)....3039
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW....3039
(H-2)....3040
ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS....3040
(H-3)....3041
NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT....3041
(H-4)....3041
ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP....3041
(H-5)....3042
AUTO-DECELERATOR DOES NOT WORK....3042
(H-6)....3042
FINE CONTROL MODE DOES NOT FUNCTION....3042
(H-7)....3043
BOOM MOVES SLOWLY OR LACKS POWER....3043
(H-8)....3044
ARM MOVES SLOWLY OR LACKS POWER....3044
(H-9)....3045
BUCKET MOVES SLOWLY OR LACKS POWER....3045
(H-10)....3046
WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION....3046
(H-11)....3047
WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT....3047
(H-12)....3048
WORK EQUIPMENT HAS EXCESSIVE LAG TIME....3048
(H-13)....3049
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT....3049
(H-14)....3049
ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE....3049
(H-15)....3049
IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY....3049
(H-16)....3050
IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY....3050
(H-17)....3050
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY....3050
(H-18)....3051
MACHINE SWERVES WHEN TRAVELING....3051
(H-19)....3052
MACHINE TRAVELS SLOWLY....3052
(H-20)....3053
MACHINE CANNOT BE STEERED EASILY OR LACKS POWER....3053
(H-21)....3054
TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING....3054
(H-22)....3054
TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY)....3054
(H-23)....3055
MACHINE DOES NOT SWING....3055
(H-24)....3056
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW....3056
(H-25)....3057
EXCESSIVE OVERRUN WHEN STOPPING SWING....3057
(H-26)....3058
THERE IS A SUDDEN SHOCK WHEN STOPPING SWING....3058
(H-27)....3058
ABNORMAL NOISE CAUSED WHEN STOPPING SWING....3058
(H-28)....3059
SWING NATURAL DRIFT IS EXCESSIVE....3059
30 DISASSEMBLY AND ASSEMBLY....3061
METHOD OF USING MANUAL....3063
PRECAUTIONS DURING OPERATION....3065
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK....3065
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK....3066
PRECAUTIONS WHEN COMPLETING THE OPERATIONS....3067
OTHER PRECAUTIONS....3067
SPECIAL TOOL LIST....3068
SKETCHES OF SPECIAL TOOLS....3071
CONNECTOR REPAIR PROCEDURES....3073
CONTACT TERMINAL REMOVAL (HD30 TYPE)....3073
STRIPING INSULATION....3074
CRIMPING CONTACT TERMINAL (HD30 TYPE)....3075
INSERTION OF CONTACT TERMINAL (HD30 TYPE)....3076
CONTACT TERMINAL REMOVAL (DT TYPE)....3077
STRIPING INSULATION....3078
CRIMPING CONTACT TERMINAL (DT TYPE)....3079
INSERTION OF CONTACT TERMINAL (DT TYPE)....3080
ENGINE....3081
ALTERNATOR....3081
CYLINDER HEAD....3081
ENGINE FRONT SEAL....3081
ENGINE OIL COOLER....3081
ENGINE REAR SEAL....3081
FUEL INJECTION PUMP....3081
NOZZLE HOLDER....3081
STARTING MOTOR....3081
THERMOSTAT....3081
TURBOCHARGER....3081
WATER PUMP....3081
RADIATOR....3082
REMOVAL....3082
INSTALLATION....3083
HYDRAULIC OIL COOLER....3084
REMOVAL....3084
INSTALLATION....3085
ENGINE AND HYDRAULIC PUMPS....3086
REMOVAL....3086
INSTALLATION....3090
FINAL DRIVE....3091
REMOVAL....3091
INSTALLATION....3091
DISASSEMBLY....3092
ASSEMBLY....3096
TRAVEL MOTOR....3102
DISASSEMBLY....3102
ASSEMBLY....3106
SWING MOTOR....3116
REMOVAL....3116
INSTALLATION....3116
DISASSEMBLY....3117
ASSEMBLY....3119
SWING MACHINERY....3126
REMOVAL....3126
INSTALLATION....3126
DISASSEMBLY....3127
ASSEMBLY....3130
IDLER AND RECOIL SPRING....3135
REMOVAL....3135
INSTALLATION....3135
IDLER....3136
RECOIL SPRING....3140
TRACK ROLLER....3142
REMOVAL....3142
INSTALLATION....3142
DISASSEMBLY....3143
ASSEMBLY....3144
SPROCKET....3147
REMOVAL....3147
INSTALLATION....3147
TRACK SHOE....3148
EXPANSION OF TRACK SHOE....3148
ASSEMBLY....3149
SWING CIRCLE....3150
REMOVAL....3150
INSTALLATION....3150
REVOLVING FRAME....3151
REMOVAL....3151
INSTALLATION....3153
CENTER SWIVEL JOINT....3154
REMOVAL....3154
INSTALLATION....3155
DISASSEMBLY....3156
ASSEMBLY....3156
HYDRAULIC TANK....3157
REMOVAL....3157
INSTALLATION....3158
CONTROL VALVE....3159
REMOVAL....3159
INSTALLATION....3161
REPLACING PRESSURE COMPENSATION VALVE SEAL....3162
ASSEMBLY....3163
HYDRAULIC PUMP....3164
REMOVAL....3164
INSTALLATION....3166
INPUT SHAFT OIL SEAL....3167
WORK EQUIPMENT PPC VALVE....3168
ASSEMBLY....3168
TRAVEL PPC VALVE....3169
ASSEMBLY....3169
HYDRAULIC CYLINDER....3170
DISASSEMBLY....3170
ASSEMBLY....3172
WORK EQUIPMENT....3176
REMOVAL....3176
INSTALLATION....3177
AIR CONDITIONER....3179
REMOVAL....3179
INSTALLATION....3182
COUNTERWEIGHT....3183
REMOVAL....3183
INSTALLATION....3183
OPERATOR’S CAB....3184
REMOVAL....3184
INSTALLATION....3186
MONITOR....3187
REMOVAL....3187
INSTALLATION....3187
GOVERNOR PUMP CONTROLLER....3188
REMOVAL....3188
INSTALLATION....3188
90 OTHERS....3189
ELECTRICAL....3191
ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 3) FOLDOUT 1....3191
ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 3) FOLDOUT 2....3193
ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 3) FOLDOUT 3....3195
ELECTRICAL DIAGRAM 2/4 (SHEET 1 OF 1) FOLDOUT 4....3197
ELECTRICAL DIAGRAM 3/4 (SHEET 1 OF 2) FOLDOUT 5....3199
ELECTRICAL DIAGRAM 3/4 (SHEET 2 OF 2) FOLDOUT 6....3201
ELECTRICAL DIAGRAM 4/4 (SHEET 1 OF 2) FOLDOUT 7....3203
ELECTRICAL DIAGRAM 4/4 (SHEET 2 OF 2) FOLDOUT 8....3205
HYDRAULIC....3207
HYDRAULIC DIAGRAM (SHEET 1 OF 3) FOLDOUT 9....3207
HYDRAULIC DIAGRAM (SHEET 2 OF 3) FOLDOUT 10....3209
HYDRAULIC DIAGRAM (SHEET 3 OF 3) FOLDOUT 11....3211
Komatsu Hydraulic Excavator PC300LC-7L, PC300HD-7L, PC300LL-7L Repair Service Manuals
