Komatsu Hydraulic Excavators PC300, PC300LC, PC350, PC350LC, PC350HD, PC350LCD, PC350NLC, PC350NLCD Series Repair Service Manuals
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Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC300, PC300LC, PC350, PC350LC, PC350HD, PC350LCD, PC350NLC, PC350NLCD Series, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6, PC300-7, PC300LC-7, PC350-7, PC350LC-7, PC300-8, PC300LC-8, PC350-8, PC350LC-8, PC350HD-8, PC350LCD-8, PC350NLC-8, PC350NLCD-8 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.
CEAM021801 - Hydraulic Excavator PC350LC-8, PC350HD-8 Operation & Maintenance Manual.pdf
CEBM007501 - Hydraulic Excavator PC350LC-8, PC350HD-8 Shop Manual.pdf
SEAM009000 - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Operation & Maintenance Manual.pdf
SEAM009001 - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Operation & Maintenance Manual.pdf
SEAM009003T - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Operation & Maintenance Manual.pdf
SEAM046000T - Hydraulic Excavator GALEO PC300-7, PC300LC-7, PC350-7, PC350LC-7 Operation & Maintenance Manual.pdf
SEBM006603 - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Shop Manual.pdf
SEBM014307 - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Shop Manual.pdf
SEBM025800 - Hydraulic Excavator PC300, 300LC-7, PC350, PC350LC-7 Shop Manual.pdf
SEBM025800 - Hydraulic Excavator PC300-7, PC300LC-7, PC350-7, PC350LC-7 Shop Manual.pdf
SEBM025811 - Hydraulic Excavator PC300-7, PC300LC-7, PC350-7, PC350LC-7 Shop Manual.pdf
SEN01983-01 - Hydraulic Excavator PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual.pdf
SEN01983-03 - Hydraulic Excavator GALEO PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual.pdf
SEN01983-04 - Hydraulic Excavator PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual.pdf
SEN01983-15 - Hydraulic Excavator PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual.pdf
TEN00055-02 - Hydraulic Excavator GALEO PC300-7, PC300LC-7, PC350-7, PC350LC-7 Operation & Maintenance Manual.pdf
TEN00056-02 - Hydraulic Excavator GALEO PC300-7, PC300LC-7, PC350-7, PC350LC-7 Operation & Maintenance Manual.pdf
TEN00182-03 - Hydraulic Excavator PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual.pdf
UEN01983-03 - Hydraulic Excavator PC350LC-8, PC350LCD-8, PC350NLC-8, PC350NLCD-8 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 11,450 pages
File Format: PDF
Language: English
CEAM021801 - Hydraulic Excavator PC350LC-8, PC350HD-8 Operation & Maintenance Manual...3
CEAM021801...3
INTRODUCTION...5
FOREWORD...6
SAFETY INFORMATION...7
INTRODUCTION...9
Directions Of Machine...9
Protective Structure...9
Breaking-in The New Machine...10
Product Information...11
Product Identification Number (Pin)/machine Serial No. Plate...11
EPA Regulations, Engine Number Plate...11
Service Meter Location...12
Your Machine Serial Numbers And Distributor...12
SAFETY...21
SAFETY AND WARNING DECALS...22
Location of the Safety Decals...22
Safety Labels...24
Optional Systems Decal...31
Optional Decal Locations...34
SAFETY INFORMATION...35
Safety Rules...35
If Problems are Found...35
Working Wear and Personal Protective Items...35
Fire Extinguisher and First Aid Kit...35
Safety Equipment...36
Keep Machine Clean...36
Keep Operator's Compartment Clean...36
Fire Prevention and Explosion Prevention...36
Action if Fire Occurs...37
Handrails and Steps...38
Precautions when Working in High Places...38
Mounting and Dismounting...38
No Persons on Attachments...39
Precautions when Standing up from Operator's Seat...39
Leaving Operator's Seat with Lock...39
Emergency Exit from Operator's Cab...39
Do Not get Caught in Articulated Portion...40
Precautions Related to Protective Structures...40
Protection Against Falling, Flying, Intruding Objects...40
Unauthorized Modification...41
Precautions Related to Attachments And Options...41
Precautions Related to Cab Glass...41
Precautions when Running Engine inside Building...42
Safety at Jobsite...42
Working on Loose Ground...42
Distance to High Voltage Cables...43
Ensure Good Visibility...43
Signalman's Signal And Signs...44
Asbestos Dust Hazard Prevention...44
Ventilation for Enclosed Area...44
SAFETY MACHINE OPERATION...45
Starting Engine...45
Checks before Starting Engine...45
Safety Rules for Starting Engine...46
Starting Engine in Cold Weather...46
Starting with Booster Cables...46
OPERATION...47
Checks Before Operation...47
Safety Rules for Changing Machine Directions...47
Safety Rules for Traveling...49
Traveling on Slopes...50
Operations on Slopes...51
Prohibited Operations...51
Operations on Snow or Frozen Surfaces...53
Parking Machine...54
TRANSPORTATION...55
Loading and Unloading...55
Shipping the Machine...56
TOWING...56
Safety Rules for Towing...56
LIFTING OBJECTS WITH BUCKET...57
Safety Rules for Lifting Objects...57
SAFETY MAINTENANCE INFORMATION...58
Warning Tag...58
Keep Work Place Clean and Tidy...58
Select Suitable Place for Inspection and Maintenance...58
Only Authorized Personnel...58
Appoint Leader when Working with Others...58
Stop Engine Before Carrying Out Maintenance...59
Two Workers for Maintenance when Engine is Running...60
Attachments...60
Working at High Places...60
Work Under the Machine...61
Proper Tools...61
Battery...62
Battery Hazard Prevention...62
Starting Engine with Booster Cables...63
When Using Hammer...63
Burn Prevention...64
Safety Rules for High-pressure Oil...64
Precaution for High Fuel Pressure...65
Safety Handling High-pressure Hoses...65
Precaution for High Voltage...65
Noise...65
Safety First when using High-pressure Grease to Adjust Track Tension...66
Do not Disassemble Recoil Springs...66
Accumulator, Gas Spring...67
Compressed Air...67
Air Conditioner Maintenance...67
Personnel...67
Welding Works...67
Disconnecting Battery Cables...67
Waste Materials...68
Mercury Containing Component(s)...68
Windshield Washer Fluid...68
Periodic Replacement Of Safety Critical Parts...68
OPERATION...69
MACHINE VIEW ILLUSTRATIONS...70
OVERALL MACHINE VIEW...70
Controls And Gauges...71
Machine Monitor...72
DETAILED CONTROLS AND GAUGES...73
Monitoring System...73
Basic Operation Of Machine Monitor...74
Emergency Monitors...79
Caution Monitors...81
Basic Check Monitors...84
Meter Display Portion...86
Gauges and Meter...90
Monitor Switches Portion...94
Maintenance Selector Switch...110
SWITCHES...142
CONTROL LEVERS AND PEDALS...147
SUN ROOF...150
WINDSHIELD...150
EMERGENCY ESCAPE HAMMER...156
DOOR LOCK...156
CAP WITH LOCK...157
DRINK BOX...159
MAGAZINE BOX...159
ASHTRAY...159
AIR CONDITIONER CONTROLS...160
Air Conditioner Control Panel...160
Method of Operation...165
Automatic Operation...165
Stopping Automatic Operation...166
Manual Operation...166
Stopping Manual Operation...168
Operation with Cold Air to Face and Warm Air to Feet...168
Defroster Operation...170
RADIO...173
Control Panel...173
Controls Of Radio...175
AUXILIARY ELECTRIC POWER...178
24 V Power Source...178
12 V Power Source...178
FUSE...179
FUSIBLE LINK...180
CONTROLLER...180
TOOL BOX...181
GREASE PUMP HOLDER...181
FIRE EXTINGUISHER...181
MACHINE OPERATIONS AND CONTROLS...182
Before Starting Engine...182
Walk-Around Checks...182
Checks Before Starting...184
Adjustment...192
Seat Adjustment...192
Adjusting Angle Of Rear View Camera...194
Rear View Mirrors...196
Seat Belt Inspection...199
Seat Belt...200
Operations Before Starting Engine...201
STARTING ENGINE...203
Turbo Protect Function...205
After Starting Engine...206
Breaking-in the New Machine...206
Engine Warm Up...207
Hydraulic System Warm-up...209
Operation After Completion Of Warming-up Operation...215
Stopping The Engine...217
MACHINE OPERATION...218
Preparations For Moving The Machine...218
Moving Machine Forward...219
Moving Machine Backward...220
Stopping Machine...221
Steering The Machine...222
Swinging...224
Work Equipment Controls And Operations...225
Working Mode...227
Prohibited Operations...229
General Operation Information...234
Traveling On Slopes...236
Escape From Mud...238
Recommended Applications...239
BUCKET REPLACEMENT AND INVERSION...241
Replacement...241
Inversion...243
PARKING MACHINE...245
MACHINE INSPECTION AFTER DAILY WORK...247
Locking...247
TRANSPORTATION...248
Transportation Procedure...248
Long Distance Transport Mode...249
Normal Mode Display...249
Long Distance Transport Mode Display...249
Loading And Unloading With Trailer...251
Loading...252
Securing Machine...255
Unloading...258
LIFTING MACHINE...260
TRANSPORTATION POSTURE...262
COLD WEATHER OPERATION...264
AFTER DAILY WORK COMPLETION...266
AFTER COLD WEATHER SEASON...266
LONG TERM STORAGE...267
Before Storage...267
During Storage...267
After Storage...268
Starting Machine After Long-term Storage...268
TROUBLES AND ACTIONS...269
Running Out Of Fuel...269
Phenomena That Are Not Failures...270
Towing The Machine...271
Lightweight Towing Hole...272
Severe Job Condition...272
Discharged Battery...273
Starting Engine With Booster Cables...275
OTHER TROUBLE...277
Electrical System...277
Chassis...278
Engine...279
Electronic Control System...280
MAINTENANCE...283
MAINTENANCE INFORMATION...284
OUTLINE OF SERVICE...286
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...286
Oil...286
Fuel...287
Coolant and Water for Dilution...287
Grease...288
Carrying out KOWA (Komatsu Oil Wear Analysis)...288
KOWA Analysis Items...288
Oil Sampling...289
Storing Oil and Fuel...289
Filters...289
Electric System Maintenance...289
WEAR PARTS...290
Wear Parts List...290
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...291
TIGHTENING TORQUE SPECIFICATIONS...294
Tightening Torque List...294
SAFETY CRITICAL PARTS...295
MAINTENANCE SCHEDULE...296
Maintenance Schedule Chart...296
Maintenance Interval for Hydraulic Breaker...298
MAINTENANCE PROCEDURE...299
Initial 1000 Hours Maintenance (Only After The First 1000 Hours)...299
When Required...300
Check, Clean and Replace Air Cleaner Element...300
Clean inside of Cooling System...306
Check and Tighten Track Shoe Bolts...310
Check and Adjust Track Tension...311
Replace Bucket Teeth (Vertical Pin Type)...313
Replace Bucket Teeth (Horizontal Pin Type)...316
Replace Bucket Side Cutter, Shroud...318
Adjust Bucket Clearance...319
Check Window Washer Fluid Level, Add Fluid...320
Check and Maintenance Air Conditioner...321
Wash Washable Floor...322
Check Gas Spring...325
Bleeding Air from Hydraulic System...326
Check Before Starting...328
Every 50 Hours Maintenance...329
Lubricating...329
Every 250 Hours Maintenance...330
Lubricate Swing Circle...330
Check Oil Level in Swing Machinery Case, Add Oil...331
Check Oil Level in Final Drive Case, Add Oil...332
Check Level of Battery Electrolyte...333
Check Air Conditioner Compressor Belt Tension, Adjust...335
Every 500 Hours Maintenance...336
Lubricating...336
Replace Fuel Pre-filter Cartridge...338
Check Swing Pinion Grease Level, Add Grease...341
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge...342
Clean and Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins and Condenser Fins...344
Clean Air Conditioner Fresh/Recirc Filters...346
Replace Breather Element in Hydraulic Tank...347
Replace Hydraulic Tank Additional Breather Element...348
Every 1000 Hours Maintenance...349
Replace Fuel Main Filter Cartridge...349
Replace Hydraulic Oil Filter Element...351
Change Oil in Swing Machinery Case...352
Check Oil Level in Damper Case, Add Oil...353
Check all Tightening Points of Engine Exhaust Pipe Clamps...353
Check Fan Belt and Alternator Drive Belt Tension, Replace...353
Check Nitrogen Gas Charge Pressure in Accumulator (For Breaker)...353
Replace Corrosion Resistor Cartridge (If equipped)...354
Every 2000 Hours Maintenance...355
Change Oil in Final Drive Case...355
Clean Hydraulic Tank Strainer...356
Checking Charge Pressure of Nitrogen Gas in Accumulator (For Control Circuit)...357
Checking Function of Accumulator...358
Releasing Pressure in Hydraulic Circuit...360
Check Alternator...361
Check Engine Valve Clearance, Adjust...361
Check Vibration Damper...361
Every 4000 Hours Maintenance...362
Check Water Pump...362
Check Starting Motor...362
Replace Accumulator (For Control Circuit)...363
Check for Looseness of High-pressure Piping Clamp, Hardening of Rubber...364
Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber...364
Every 5000 Hours Maintenance...365
Change Oil in Hydraulic Tank...365
Every 8000 Hours Maintenance...367
Replace High-pressure Piping Clamp...367
Replace Fuel Spray Prevention Cap...367
SPECIFICATIONS...369
SPECIFICATIONS...370
OPTIONS, ATTACHMENTS...373
GENERAL PRECAUTIONS FOR SAFETY...374
Precautions When Selecting...374
Read The Instruction Manual Thoroughly...374
Precautions When Removing Or Installing...374
Precautions When Using...374
BUCKET WITH HOOK...375
Hook Condition...375
Prohibited Operations...375
MACHINE READY FOR ATTACHMENT...376
Locations...376
ATTACHMENT REMOVAL AND INSTALLATION...386
Attachment Removal...386
Attachment Installation...388
ATTACHMENT OPERATIONS...390
Long Term Storage...391
Specifications...391
ATTACHMENT GUIDE...392
Attachment Combinations...393
Track Shoes Selection...394
RECOMMENDED ATTACHMENT OPERATIONS...395
Hydraulic Breaker...395
HANDLING MACHINES EQUIPPED WITH KOMTRAX...400
CEBM007501 - Hydraulic Excavator PC350LC-8, PC350HD-8 Shop Manual...401
CEBM007501 - PC350LC-8 / PC350HD-8...401
CONTENTS...402
REVISED PAGES...403
SAFETY...413
Safety Notice...413
IMPORTANT SAFETY NOTICE...413
General Precautions...413
Preparations For Work...413
Precautions During Work...414
GENERAL...415
HOW TO READ THE SHOP MANUAL...416
Volumes...416
Distribution and Updating...416
Filing Method...416
Revised Edition Mark...416
Revisions...416
Symbols...416
HOISTING INSTRUCTIONS...417
Hoisting...417
Wire Ropes...417
PUSH PULL COUPLER...418
Type 1...418
Disconnection...418
Connection...418
Type 2...419
Disconnection...419
Connection...419
Type 3...420
Disconnection...420
Connection...420
COATING MATERIALS...421
STANDARD TIGHTENING TORQUE...423
Standard Tightening Torque of Bolts And Nuts...423
Tightening Torque of Hose Nuts...424
Tightening Torque of Split Flange Bolts...424
Tightening Torque for Flared Nuts...424
Table of Tightening Torques for O-ring Boss Piping Joints...425
Table of Tightening Torques for O-ring Boss Plugs...425
Tightening Torque Table for Hoses (Taper Seal Type and Face Seal Type)...425
ELECTRIC WIRE CODE...426
Classification by Thickness...426
Classification by Color and Code...426
CONVERSION TABLES...427
Method of Using the Conversion Table...427
01 GENERAL...433
SPECIFICATION DIMENSION DRAWINGS...434
Dimensions...434
Working Ranges...435
SPECIFICATIONS...436
WEIGHT TABLE...439
FUEL, COOLANT, AND LUBRICANTS...441
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD...443
ENGINE AND COOLING SYSTEM...446
Engine Related Parts...446
Radiator, Oil Cooler and Aftercooler...447
POWER TRAIN...448
Power Train...448
Final Drive...450
PC350LC-8...450
PC350HD-8...452
Sprocket...454
PC350LC-8...454
PC350HD-8...456
Swing Machinery...458
Swing Circle...460
UNDERCARRIAGE AND FRAME...462
Track Frame and Recoil Spring...462
PC350LC-8...462
PC350HD-8...464
Idler...466
PC350LC-8...466
PC350HD-8...468
Carrier Roller...470
PC350LC-8...470
PC350HD-8...471
Track Roller...472
PC350LC-8...472
PC350HD-8...474
Track Shoe...476
PC350LC-8...476
PC350HD-8...478
Triple Grouser Shoe...480
PC350LC-8...480
PC350HD-8...481
HYDRAULIC SYSTEM...482
Hydraulic Equipment Layout Drawing...482
Hydraulic Tank and Filter...484
Hydraulic Pump...486
Type: HPV125+125...486
LS Valve...492
PC Valve...497
LS(PC)-EPC Valve...504
Variable Volume Valve...507
Control Valve...508
CLSS (Closed Center Load Sensing System)...520
Valve Functions and Operation...524
Hydraulic Circuit Diagram and the Name of Valves...524
Unloader Valve...526
LS Pressure...528
Pressure Compensation Valve...530
Pressure Compensation Valve Inner Shuttle...533
Boom Regeneration Circuit...535
Arm Regeneration Circuit...537
Merge-divider Valve...539
LS Select Valve...541
Self Pressure Reducing Valve...542
Travel Junction Valve...545
Travel PPC Shuttle Valve...547
Boom Drift Prevention Valve...549
Arm Drift Prevention Valve...552
Quick Return Valve...556
Lift Check Valve...558
Main Relief Valve...559
2-Stage Safety-suction Valve...560
Variable Pressure Compensation Valve...562
Attachment Circuit Selector Valve...564
Drift Prevention Valve...566
Valve Control...571
PPC Valve...572
Travel PPC Valve...577
Pressure Reducing Valve...580
Service PPC Valve (with EPC Valve)...586
Service PPC Valve...592
Solenoid Valve...594
PPC Accumulator...596
Return Oil Filter...597
Center Swivel Joint...598
Travel Motor - Type: HMV160ADT-2 - PC350LC-8...600
Parking Brake - PC350LC-8...606
Travel Motor - Type: KMV200ADT-2 - PC350HD-8...614
Parking Brake - PC350HD-8...620
Safety Valve...624
Swing Motor...628
Reverse Prevention Valve...634
Hydraulic Cylinder...638
Boom Cylinder...638
Arm Cylinder...638
Bucket Cylinder...638
WORK EQUIPMENT...640
Work Equipment...640
Dimension Of Arm...642
Dimension Of Bucket...644
AIR CONDITIONER PIPING...646
ELECTRICAL SYSTEM...647
Engine Control...647
Fuel Control Dial...649
Engine Controller...650
Sensors...654
Coolant Temperature Sensor...654
Oil Pressure Switch...654
Engine Speed Sensor...655
Boost Pressure And Temperature Sensor...655
WIF (Water-in-fuel Detection) Sensor...656
Engine Oil Level Sensor...656
ELECTRONIC CONTROL SYSTEM...657
Control Function...657
System Diagram...658
Engine and Pump Control...660
Pump and Valve Control...666
LS Control Function...667
Cut-off Function...667
2-Stage Relief Function...667
Power Maximizing and Machine Push-up...668
Auto-deceleration...670
Auto-warm-up and Overheat Prevention...672
Swing Control...674
Travel Control...676
Attachment Flow Control and Circuit Selector...678
System Component Parts...679
PPC Oil Pressure Switch...679
Oil Pressure Sensor...680
Pump Pressure Sensor (High Pressure)...681
Pump Controller...682
MONITOR SYSTEM...685
Machine Monitor...686
Monitor Control, Display Portion...690
Monitor Items And Display...692
Switches...696
Sensors...713
KOMTRAX Terminal System...715
KOMTRAX Communication Modem - TH300...716
20 STANDARD VALUE TABLES...717
STANDARD VALUE TABLES...718
Engine Related...718
Chassis Related...719
30 TESTING AND ADJUSTING...727
CHASSIS SERVICE TOOLS‘...729
Sketches of special tools...733
ENGINE...734
Engine Speed...734
Air Boost Pressure...735
Exhaust Gas Color...736
Valve Clearance...738
Compression Pressure...740
Blow-by Pressure...745
Engine Oil Pressure...746
Fuel Pressure...747
Handling During Cylinder Cut-out Operation...752
Handling During No Injection Cranking Operation...752
Fuel Return Rate And Leakage...753
Bleeding Air From Fuel Circuit...756
Fuel Circuit For Leakage...757
AIR COMPRESSOR BELT TENSION...758
FAN BELT...759
ALTERNATOR BELT...760
SWING CIRCLE BEARINGS...761
TRACK SHOE TENSION...762
OIL PRESSURE IN WORK EQUIPMENT...763
OIL PRESSURE IN SWING...763
OIL PRESSURE IN TRAVEL CIRCUIT...763
CONTROL CIRCUIT OIL PRESSURE...768
PUMP PC OIL PRESSURE...769
PUMP LS OIL PRESSURE...772
SOLENOID VALVE OUTPUT PRESSURE...777
PPC VALVE OUTPUT PRESSURE...780
WORK EQUIPMENT VALVE ADJUSTMENT...781
SWING PPC VALVE ADJUSTMENT...781
HYDRAULIC DRIFT IN WORK EQUIPMENT...782
Boom and Bucket Cylinders...782
Arm Cylinder...782
Boom Lock Valve...783
PPC Valve...783
RELEASING HYDRAULIC PRESSURE...784
Oil Leakage Amount...784
BLEEDING AIR FROM VARIOUS SYSTEMS...787
DIODE INSPECTION PROCEDURES...790
MACHINE MONITOR - SPECIAL FUNCTIONS...792
Ordinary Functions and Special Functions of Machine Monitor...794
Operator Mode (Outline)...796
Display of Komatsu Logo...797
Display of Inputting Password...797
Display of Check of Breaker Mode...798
Display of Check Before Starting...798
Display of Warning After Check Before Starting...798
Display of Ending of Maintenance Interval...799
Display of Check of Working Mode and Travel Speed...799
Display of Ordinary Screen...799
Display of End Screen...800
Selection of Auto-deceleration...800
Selection of Working Mode...800
Selection of Travel Speed...801
Operation to Stop Alarm Buzzer...801
Operation of Windshield Wiper...802
Operation of Window Washer...802
Operation of Air Conditioner/heater...802
Operation to Display Camera Mode (if CameraiIs Installed)...803
Operation to Display Clock and Service Meter...803
Check of Maintenance Information...804
Setting and Display of User Mode...804
KOMTRAX Message...805
Display of Energy-saving Guidance...805
Display of Caution Monitor...805
Display of Automatic Judgment of Breaker...806
Display of User Code and Failure Code...806
Function of Checking Display of LCD (Liquid Crystal Display)...808
Function of Checking Service Meter...808
Function of Changing Attachment/Maintenance Password...809
Service Mode...811
Monitoring...813
Abnormality Record (Mechanical Systems)...818
Abnormality Record (Electrical Systems)...819
Abnormality Record (Air-conditioning System/Heater System)...827
Maintenance Record...828
Maintenance Mode Change...829
Phone Number Entry...832
Default (Key-ON Mode)...833
Default (Unit)...834
Default (With/Without Attachment)...835
Default (Attachment/Maintenance Password)...836
Default (Camera)...837
Default (ECO Display)...838
Default (Breaker Detect)...840
Adjustment (Pump Absorption Torque)...841
Adjustment (Low Speed)...842
Adjustment (Attachment Flow Adjustment)...843
Cylinder Cut-Out...844
No Injection...845
Fuel Consumption...847
KOMTRAX Settings (Terminal Status)...848
KOMTRAX Settings (GPS & Communication Status)...849
KOMTRAX Setting (Modem S/N: TH300)...850
Display of KOMTRAX Service Message...851
Long Distance Transport Mode...852
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...854
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM...855
PROCEDURE FOR TESTING DIODES...860
PM CLINIC SERVICE...861
40 TROUBLESHOOTING...867
FAILURE CODES TABLE...871
FUSE LOCATIONS...874
Connection Table of Fuse Box...874
Locations of Fusible Links...875
Location of Fuse Box and Fuse Numbers...875
GENERAL INFORMATION...878
Points to Remember when Troubleshooting...878
Sequence of Events in Troubleshooting...880
Handling Electric Equipment and Hydraulic Components...881
Connectors for Tier 3 Engines...889
Checks Before Troubleshooting...893
Classification and Troubleshooting Steps...894
Classification of Troubleshooting...894
Information in Troubleshooting Table...896
Possible Problems and Troubleshooting No...898
Connection Table for Connector Pin Numbers...901
T-adapter Box and T-adapter Table...936
FAILURE CODE (DISPLAY OF CODE)...939
989L00 - Engine Controller Lock Caution 1...939
989L00 - Engine Controller Lock Caution 2...939
989L00 - Engine Controller Lock Caution 3...940
AA10NX - Air Cleaner Clogging...942
AB00KE - Charge Voltage Low...944
B@BAZG - Engine Oil Pressure Low...946
B@BAZK - Engine Oil Level Low...948
B@BCNS - Engine Coolant Overheat...950
B@BCZK - Engine Coolant Level Low...952
B@HANS - Hydraulic Oil Overheat...954
CA111 - EMC Critical Internal Failure...956
CA115 - Engine NE and BKUP Speed Sensor Error...957
CA122 - Charge Air Pressure Sensor High Error...958
CA123 - Charge Air Pressure Sensor Low Error...960
CA131 - Throttle Sensor High Error...962
CA132 - Throttle Sensor Low Error...964
CA144 - Coolant Temperature Sensor High Error...966
CA145 - Coolant Temperature Sensor Low Error...968
CA153 - Charge Air Temperature Sensor High Error...970
CA154 - Charge Air Temperature Sensor Low Error...972
CA155 - Chg Air Temp High Speed Derate...974
CA187 - Sensor Power Supply Two Volt Low Error...976
CA221 - Ambient Pressure Sensor High Error...978
CA222 - Ambient Pressure Sensor Low Error...980
CA227 - Sensor Supply Two Volt High Error...982
CA234 - Engine Overspeed...984
CA238 - NE Speed Sensor Supply Voltage Error...985
CA271 - IMV/PCV1 Short Error...986
CA272 - IMV/PCV1 Open Error...988
CA281 - Pump Press Balance Error...990
CA322 - Injector #1 Open/short Error...992
CA323 - Injector #5 Open/short Error...994
CA324 - Injector #3 Open/short Error...996
CA325 - Injector #6 Open/short Error...998
CA331 - Injector #2 Open/short Error...1000
CA332 - Injector #4 Open/short Error...1002
CA342 - Calibration Code Incompatibility...1004
CA351 - Injectors Drive Circuit Error...1006
CA352 - Sensor Supply One Volt Low Error...1008
CA386 - Sensor Supply One Volt High Error...1010
CA428 - Water in Fuel Sensor High Error...1012
CA429 - Water in Fuel Sensor Low Error...1014
CA435 - Eng Oil Press Sw Error...1016
CA441 - Battery Voltage Low Error...1018
CA442 - Battery Voltage High Error...1020
CA449 - Rail Pressure Very High Error...1022
CA451 - Rail Pressure Sensor High Error...1026
CA452 - Rail Pressure Sensor Low Error...1028
CA488 - Chg Air Temp High Torque Derate...1030
CA553 - Rail Pressure High Error...1031
CA559 - Rail Pressure Low Error...1032
CA689 - Engine NE Speed Sensor Error...1034
CA731 - Engine BKUP Speed Sensor Phase Error...1036
CA757 - All Persistent Data Lost Error...1038
CA778 - Engine BKUP Speed Sensor Error...1040
CA1633 - KOMNET Datalink Timeout Error...1042
CA2185 - Throttle Sensor Supply Volt High Error...1044
CA2186 - Throttle Sensor Supply Volt Low Error...1046
CA2249 - Rail Pressure Very Low Error...1047
CA2265 - Electric Lift Pump High Error...1048
CA2266 - Electric Lift Pump Low Error...1050
CA2311 - IMV Solenoid Error...1052
CA2555 - Grid Htr Relay Volt High Error...1054
CA2556 - Grid Htr Relay Volt Low Error...1056
D110KB - Battery Relay Drive Short Circuit...1058
D19JKZ - Personal Code Relay Abnormality...1060
D862KA - GPS Antenna Discon...1062
DA22KK - Pump Solenoid Power Low Error...1064
DA25KP - 5 V Sensor 1 Power Abnormality...1066
DA29KQ - Model Selection Abnormality...1070
DA2RMC - Pump Communication Abnormality...1072
DAF8KB - Short Circuit in Camera Power Supply...1074
DAFGMC - GPS Module Error...1076
DAFRMC - CAN Discon (Monitor Detected)...1078
DGH2KB - Hyd Oil Sensor Short...1080
DHPAMA - F Pump Pressure Sensor Abnormality...1082
DHPBMA - R Pump Pressure Sensor Abnormality...1084
DHS3MA - Arm Curl PPC Sensor Abnormality...1086
DHS4MA - Bucket Curl PPC Pressure Sensor Abnormality...1088
DHX1MA - Overload Sensor Abnormality (Analog)...1090
DW43KA - Travel Speed Solenoid Disconnection...1092
DW43KB - Travel Speed Solenoid Short Circuit...1094
DW45KA - Swing Brake Solenoid Disconnection...1096
DW45KB - Swing Brake Solenoid Short Circuit...1100
DW91KA - Travel Junction Solenoid Disconnection...1102
DW91KB - Travel Junction Solenoid Short Circuit...1104
DWA2KA - Attachment Sol Open Circuit...1106
DWA2KB - Attachment Sol Short Circuit...1107
DWJ0KA - Merge-Divider Solenoid Disconnection...1108
DWJ0KB - Merge-Divider Solenoid Short Circuit...1110
DWK0KA - 2-Stage Relief Sol. Open Circuit...1112
DWK0KB - 2-Stage Relief Solenoid Short Circuit...1114
DXA0KA - PC-EPC Solenoid Open Circuit...1116
DXA0KB - PC-EPC Solenoid Short Circuit...1118
DXE0KA - LS-EPC Solenoid Disconnection...1120
DXE0KB - LS-EPC Solenoid Short Circuit...1122
DXE4KA - Service Current EPC Disconnection...1124
DXE4KB - Service Current EPC Short Circuit...1125
DY20KA - Wiper Working Abnormality...1126
DY20MA - Wiper Parking Abnormality...1128
DY2CKA - Washer Drive Open Circuit...1130
DY2CKB - Washer Drive Short Circuit...1132
DY2DKB - Wiper Motor Drive Forward System Short...1134
DY2EKB - Wiper Drive Reverse Short Circuit...1136
E-MODE (ELECTRICAL SYSTEM)...1138
Information Contained in Troubleshooting Table...1138
E-1 Engine Does Not Start...1140
E-2 Auto-decelerator Does Not Operate...1143
E-3 Automatic Warming-up System Does Not Operate...1145
E-4 Preheater Does Not Operate...1146
E-5 All Work Equipment, Swing, and Travel Mechanism do not move...1148
E-6 Power Maximizing Function Does Not Operate...1150
E-7 Machine Monitor Does Not Display At All...1152
E-8 Machine Monitor Does Not Display Some Items...1154
E-9 Contents of Display by Machine Monitor are Different from Applicable Machine...1154
E-10 Fuel Level Monitor Was Lit in Red While Engine Running...1155
E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally...1156
E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally...1158
E-13 Fuel Level Gauge Does Not Indicate Normally...1159
E-14 Swing Lock Monitor Does Not Indicate Normally...1160
E-15 When Monitor Switch is Operated, Monitor Displays Nothing...1162
E-16 Windshield Wiper and Window Washer do not Operate...1164
E-17 Machine Push-up Function Does Not Operate Normally...1168
E-18 Monitoring Function Fails to Display “Boom Raise” Normally...1170
E-19 Monitoring Function Fails to Display “Boom Lower” Normally...1172
E-20 Monitoring Function Fails to Display “Arm In” Normally...1174
E-21 Monitoring Function Fails to Display “Arm Out” Normally...1176
E-22 Monitoring Function Fails to Display “Bucket Curl” Normally...1178
E-23 Monitoring Function Fails to Display “Bucket Dump” Normally...1180
E-24 Monitoring Function Fails to Display “Swing” Normally...1182
E-25 Monitoring Function Fails to Display “Travel” Normally...1184
E-26 Monitoring Function Fails to Display “Travel Differential Pressure” Normally...1186
E-27 Monitoring Function Fails to Display “Service” Normally...1188
E-28 KOMTRAX System Does Not Operate Normally...1190
E-29 Air Conditioner Does Not Operate...1192
E-30 Travel Alarm Does Not Sound or Does Not Stop Sounding...1194
E-31 Horn Does Not Sound...1196
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)...1198
System Chart for Hydraulic and Mechanical System...1198
Information Contained in Troubleshooting Table...1200
H-1 All Work Equipment Lack Power, or Travel and Swing Speeds are Slow...1202
H-2 Engine Speed Sharply Drops or Engine Stalls...1204
H-3 No Work Equipment, Swing or Travel Move...1205
H-4 Abnormal Noise is Heard from Around Hydraulic Pump...1205
H-5 Auto-decelerator Does Not Work...1206
H-6 Fine Control Mode Does Not Function or Responds Slow...1206
H-7 Boom Moves Slowly or Lacks Power...1207
H-8 Arm Moves Slowly or Lacks Power...1208
H-9 Bucket Moves Slowly or Lacks Power...1209
H-10 Work Equipment Does Not Move in its Single Operation...1209
H-11 Work Equipment has a bit too Fast Hydraulic Drift...1210
H-12 Work Equipment Has Big Time Lag...1212
H-13 Other Work Equipment Moves When Relieving Single Circuit...1212
H-14 Power Max. Switch Does Not Operate...1213
H-15 In Compound Operation, Work Equipment with Larger Load Moves Slowly...1213
H-16 In Swing + Boom Raise Operation, Boom Moves Slowly...1214
H-17 In Swing + Travel Operation, Travel Speed Drops Sharply...1214
H-18 Machine Swerves in Travel...1215
H-19 Machine Travels Slowly...1216
H-20 Machine Cannot Be Easily Steered or Lacks Power...1217
H-21 Travel Speed Does Not Shift, or it is too Slow or Fast...1218
H-22 Track Shoe Does Not Turn (On One Side Only)...1219
H-23 Machine Does Not Swing...1220
H-24 Swing Acceleration is Poor, or Swing Speed is Slow...1222
H-25 Excessive Overrun When Stopping Swing...1224
H-26 There is Big Shock when Stopping Swing...1225
H-27 Large Sound is made when Upper Structure Stops Swinging...1225
H-28 Swing Hydraulic Drift is too big...1226
50 DISASSEMBLY AND ASSEMBLY...1227
HOW TO READ THIS MANUAL...1230
SPECIAL TOOLS LIST...1233
SKETCHES OF SPECIAL TOOLS...1237
CONNECTOR REPAIR PROCEDURES...1240
Contact Terminal Removal (HD30 Type)...1240
Striping Insulation...1241
Crimping Contact Terminal (HD30 Type)...1242
Insertion Of Contact Terminal (HD30 Type)...1243
Contact Terminal Removal (DT Type)...1244
ENGINE COMPONENTS...1245
Fuel Supply Pump...1245
Removal...1245
Installation...1247
Engine Front Seal...1249
Removal...1249
Installation...1251
Engine Rear Seal...1253
Removal...1253
Installation...1255
Cylinder Head...1259
Removal...1259
Installation...1265
RADIATOR...1274
Removal...1274
Installation...1275
HYDRAULIC OIL COOLER...1276
Removal...1276
Installation...1277
AFTERCOOLER...1278
Removal...1278
Installation...1278
ENGINE AND HYDRAULIC PUMP...1279
Removal...1279
Installation...1284
FINAL DRIVE...1285
Removal...1285
Installation...1285
Disassembly...1286
Assembly...1291
SWING MOTOR AND SWING MACHINERY...1298
Removal...1298
Installation...1299
Disassembly...1300
Assembly...1304
SWING CIRCLE...1310
Removal...1310
Installation...1310
CARRIER ROLLER...1311
Disassembly...1311
Assembly...1311
TRACK ROLLER...1313
Disassembly...1313
Assembly...1313
IDLER...1315
Disassembly...1315
Assembly...1316
RECOIL SPRING...1319
Disassembly...1319
Assembly...1320
SPROCKET...1322
Removal...1322
Installation...1322
TRACK SHOE...1323
Expansion...1323
Installation...1324
REVOLVING FRAME...1325
Removal...1325
Installation...1327
COUNTERWEIGHT...1328
Removal...1328
Installation...1329
CENTER SWIVEL JOINT...1330
Removal...1330
Installation...1331
Disassembly...1332
Assembly...1333
HYDRAULIC TANK...1334
Removal...1334
Installation...1336
CONTROL VALVE...1337
Removal...1337
Installation...1340
Disassembly...1340
Assembly...1340
HYDRAULIC PUMP...1343
Removal...1343
Installation...1345
Oil Seal in Hydraulic Pump input Shaft...1346
Removal...1346
Installation...1346
WORK EQUIPMENT PPC VALVE...1347
Disassembly...1347
Assembly...1347
TRAVEL PPC VALVE...1350
Disassembly...1350
Assembly...1351
HYDRAULIC CYLINDER...1353
Disassembly...1353
Assembly...1356
WORK EQUIPMENT...1360
Removal...1360
Installation...1362
CAB...1363
Removal...1363
Installation...1366
Cab Glass (Stuck Glass)...1367
Removal...1368
Installation...1369
Front Window...1379
Removal...1379
Installation...1382
Floor Frame...1387
Removal...1387
Installation...1391
ELECTRICAL SYSTEM...1392
Air Conditioner Unit...1392
Removal...1392
Installation...1395
KOMTRAX Communication Modem...1396
Removal...1396
Installation...1396
Monitor...1397
Removal...1397
Installation...1398
Pump Controller...1399
Removal...1399
Installation...1400
Engine Controller...1402
Removal...1402
Installation...1402
60 AIR CONDITIONER...1403
STRUCTURE AND FUNCTION...1406
Air Conditioner Component...1406
Configuration and Function of Refrigerating cycle...1408
Outline of Refrigerating Cycle...1409
Air Conditioner Unit...1412
Functions of Major Components in the Air Conditioner Unit...1414
Control Plate...1416
Compressor...1419
Condenser and Receiver Drier...1420
TESTING AND ADJUSTING...1421
Caution About Refrigerant...1421
Troubleshooting Procedure...1422
Block Diagram...1423
Circuit Diagram and Arrangement of Connector Pins...1424
Detail of Air Conditioner Unit...1426
Part and Connector Locations...1428
Testing Air Leakage (Ducts)...1432
Testing with Self-diagnosis Function...1434
Testing Temperature Control...1437
Testing Vent (Mode) Changeover...1440
Testing Recirc/Fresh Changeover...1444
Testing Inner Sensor...1446
Testing Evaporator Temperature Sensor...1447
Testing Sunlight Sensor...1449
Testing (Dual) Pressure Switch for Refrigerant...1450
Testing Relays...1452
TROUBLESHOOTING...1454
Troubleshooting Chart 1...1454
Troubleshooting Chart 2...1455
Troubleshooting for Electrical System (E mode)...1458
E-1 Power Supply System (Air Conditioner does not Operate)...1459
E-2 Compressor System (Air is Not Cooled)...1463
E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)...1466
E-4 Temperature Cannot be Controlled...1470
E-5 Vent (Mode) Cannot be Changed Over...1473
E-6 Recirc/Fresh Air Cannot be Changed Over...1476
Troubleshooting With Gauge Pressure...1479
Connection of Service Tool...1482
Precautions for connecting air conditioner piping...1484
Handling of Compressor Oil...1485
Control of Compressor Oil...1485
Adding of Compressor Oil...1485
Compressor Replacement...1486
Applying Compressor Oil for O-ring...1486
Desiccant Replacement Procedure...1487
90 DIAGRAMS AND DRAWINGS...1489
HYDRAULIC SYSTEM...1491
Hydraulic Circuit Diagram - PC350LC/HD-8...1491
ELECTRICAL SYSTEM...1492
Electrical Circuit Diagram (1/5)...1492
Electrical Circuit Diagram (2/5)...1493
Electrical Circuit Diagram (3/5)...1494
Electrical Circuit Diagram (4/5)...1495
Electrical Circuit Diagram (5/5)...1496
Connector Arrangement Diagram - PC350LC/HD-8...1497
SEAM009000 - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Operation & Maintenance Manual...1498
COVER...1498
1. FOREWORD...1499
2. SAFETY INFORMATION...1500
3. INTRODUCTION...1501
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...1502
5. CONTENTS...1503
SAFETY...1507
6. GENERAL PRECAUTIONS...1508
7. PRECAUTIONS DURING OPERATION...1514
7.1 BEFORE STARTING ENGINE...1514
7.2 OPERATING MACHINE...1516
7.3 TRANSPORTATION...1521
7.4 BATTERY...1522
7.5 TOWING...1523
7.6 BUCKET WITH HOOK...1524
8. PRECAUTIONS FOR MAINTENANCE...1527
8.1 BEFORE CARRYING OUT MAINTENANCE...1527
8.2 DURING MAINTENANCE...1530
9. POSITION FOR ATTACHING SAFETY LABELS...1534
OPERATION...1538
10. GENERAL VIEW...1539
10.1 GENERAL VIEW OF MACHINE...1539
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...1540
11. EXPLANATION OF COMPONENTS...1541
11.1 MACHINE MONITOR...1541
11.2 SWITCHES...1552
11.3 CONTROL LEVERS,PEDALS...1556
11.4 CEILING WINDOW...1561
11.5 FRONT WINDOW...1562
11.6 DOOR LOCK...1564
11.7 CAP, COVER WITH LOCK...1565
11.8 HOT AND COOL BOX...1566
11.9 LUGGAGE BOX...1566
11.10 ASHTRAY...1566
11.11 HANDLING AIR CONDITIONER...1567
11.12 CAR RADIO...1570
11.13 FUSE...1575
11.14 FUSIBLE LINK...1576
11.15 CONTROLLERS...1576
11.16 TOOL BOX...1576
11.17 GREASE GUN HOLDER...1576
11.18 HANDLING ACCUMULATOR...1577
12. OPERATION...1578
12.1 CHECK BEFORE STARTING ENGINE...1578
12.2 STARTING ENGINE...1589
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...1592
12.4 MOVING MACHINE OFF...1598
12.5 STEERING MACHINE...1601
12.6 STOPPING MACHINE...1603
12.7 SWINGING...1604
12.8 OPERATION OF WORK EQUIPMENT...1605
12.9 HANDLING WORKING MODE...1606
12.10 PROHIBITIONS FOR OPERATION...1608
12.11 PRECAUTIONS FOR OPERATION...1610
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...1611
12.13 HOW TO ESCAPE FROM MUD...1613
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...1614
12.15 REPLACEMENT AND INVERSION OF BUCKET...1615
12.16 PARKING MACHINE...1617
12.17 CHECK AFTER FINISHING WORK...1618
12.18 STOPPING ENGINE...1619
12.19 CHECK AFTER STOPPING ENGINE...1620
12.20 LOCKING...1620
13. TRANSPORTATION...1621
13.1 LOADING,UNLOADING WORK...1621
13.2 PRECAUTIONS FOR LOADING...1623
13.3 PRECAUTIONS FOR TRANSPORTATION...1623
14. COLD WEATHER OPERATION...1624
14.1 PRECAUTIONS FOR LOW TEMPERATURE...1624
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...1626
14.3 AFTER COLD WEATHER...1626
15. LONG-TERM STORAGE...1627
15.1 BEFORE STORAGE...1627
15.2 DURING STORAGE...1628
15.3 AFTER STORAGE...1628
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE...1628
16. TROUBLESHOOTING...1629
16.1 PHENOMENA THAT ARE NOT FAILURES...1629
16.2 METHOD OF TOWING MACHINE...1629
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE...1629
16.4 PRECAUTIONS ON PARTICULAR JOBSITES...1630
16.5 IF BATTERY IS DISCHARGED...1630
16.6 OTHER TROUBLE...1634
MAINTENANCE...1639
17. GUIDES TO MAINTENANCE...1640
18. OUTLINES OF SERVICE...1643
18.1 OUTLINE OF OIL,FUEL,COOLANT...1643
18.2 OUTLINE OF ELECTRIC SYSTEM...1646
18.3 OUTLINE OF HYDRAULIC SYSTEM...1647
19. WEAR PARTS LIST...1648
20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...1650
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...1654
21.1 INTRODUCTION OF NECESSARY TOOLS...1654
21.2 TORQUE LIST...1655
22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS...1656
23. MAINTENANCE SCHEDULE CHART...1658
23.1 MAINTENANCE SCHEDULE CHART...1658
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER...1660
24. SERVICE PROCEDURE...1661
24.1 INITIAL 250 HOURS SERVICE...1661
24.2 WHEN REQUIRED...1662
24.3 CHECK BEFORE STARTING...1680
24.4 EVERY 50 HOURS SERVICE...1684
24.5 EVERY 100 HOURS SERVICE...1686
24.6 EVERY 250 HOURS SERVICE...1688
24.7 EVERY 500 HOURS SERVICE...1696
24.8 EVERY 1000 HOURS SERVICE...1703
24.9 EVERY 2000 HOURS SERVICE...1706
24.10 EVERY 4000 HOURS SERVICE...1713
SPECIFICATIONS...1714
25. SPECIFICATIONS...1715
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 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...1724
27.2 PROHIBITED OPERATIONS...1724
27.3 PRECAUTIONS DURING OPERATIONS...1724
28. USING SEAT BELT...1725
28.1 SEAT BELT...1725
29. HANDLING CAR HEATER...1727
29.1 GENERAL LOCATIONS...1727
29.2 PREPARATION FOR CAR HEATER...1728
30. MACHINES READY FOR ATTACHMENT...1729
30.1 GENERAL LOCATIONS...1729
30.2 HYDRAULIC CIRCUIT...1731
30.3 PROCEDURE FOR REMOVAL AND INSTALATION OF ATTACHMENT ...1733
30.4 OPERATION...1735
30.5 LONG TERM STORAGE...1736
30.6 SPECIFICATIONS...1736
31. INTRODUCTION OF ATTACHMENTS...1737
31.1 SPECIFICATION, USE...1737
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE...1739
31.3 SELECTION OF TRACK SHOES...1741
31.4 SELECTION OF BUCKET TEETH...1742
31.5 HANDLING TRAPEZOIDAL BUCKET...1743
32. EXTENDING MACHINE SERVICE LIFE...1744
32.1 HYDRAULIC BREAKER...1744
32.2 POWER RIPPER...1747
32.3 FORK GRAB...1748
32.4 GRAPPLE BUCKET...1749
32.5 SCRAP GRAPPLE...1750
32.6 CRUSHER AND CUTTER...1751
32.7 HYDRAULIC PILE DRIVER...1752
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE...1753
33. AUTO-GREASING SYSTEM...1754
33.1 AUTO-GREASING CONTROLLER...1754
33.2 ACTION WHEN ABNORMALITY OCCURS...1755
33.3 CHECK BEFORE STARTING...1756
33.4 EVERY 50 HOURS SERVICE...1758
SEAM009001 - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Operation & Maintenance Manual...1759
COVER...1759
1. FORWORD...1760
2. SAFETY INFORMATION...1761
3. INTRODUCTION...1762
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...1763
5. CONTENTS...1764
SAFETY...1768
6. GENERAL PRECAUTIONS...1769
7. PRECAUTIONS DURING OPERATION...1778
7.1 BEFORE STARTING ENGINE...1778
7.2 AFTER STARTING ENGINE...1780
7.3 TRANSPORTATION...1788
7.4 BATTERY...1790
7.5 TOWING...1792
7.6 BUCKET WITH HOOK...1793
8. PRECAUTIONS FOR MAINTENANCE...1794
8.1 BEFORE CARRYING OUT MAINTENANCE...1794
8.2 DURING MAINTENANCE...1799
9. POSITION FOR ATTACHING SAFETY LABELS...1806
OPERATION...1812
10. GENERAL VIEW...1813
10.1 GENERAL VIEW OF MACHINE...1813
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...1814
11. EXPLANATION OF COMPONENTS...1815
11.1 MACHINE MONITOR...1815
11.2 SWITCHES...1826
11.3 CONTROL LEVERS, PEDALS...1830
11.4 CEILING WINDOW...1835
11.5 FRONT WINDOW...1836
11.6 DOOR LOCK...1838
11.7 CAP, COVER WITH LOCK...1839
11.8 HOT AND COOL BOX...1840
11.9 LUGGAGE BOX...1840
11.10 ASHTRAY...1840
11.11 HANDLING AIR CONDITIONER...1841
11.12 CAR RADIO...1844
11.13 ELECTRIC POWER TAKE-OUT ADAPTER...1848
11.14 FUSE...1849
11.15 FUSIBLE LINK...1850
11.16 CONTROLLERS...1850
11.17 TOOL BOX...1850
11.18 GREASE GUN HOLDER...1850
11.19 HANDLING ACCUMULATOR...1851
12. OPERATION...1852
12.1 CHECK BEFORE STARTING ENGINE...1852
12.2 STARTING ENGINE...1863
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...1866
12.4 MOVING MACHINE OFF...1872
12.5 STEERING MACHINE...1875
12.6 STOPPING MACHINE...1877
12.7 SWINGING...1878
12.8 OPERATION OF WORK EQUIPMENT...1879
12.9 HANDLING ACTIVE MODE...1880
12.10 HANDLING WORKING MODE...1881
12.11 PROHIBITIONS FOR OPERATION...1883
12.12 PRECAUTIONS FOR OPERATION...1885
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...1886
12.14 HOW TO ESCAPE FROM MUD...1888
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...1889
12.16 REPLACEMENT AND INVERSION OF BUCKET...1890
12.17 PARKING MACHINE...1892
12.18 CHECK AFTER FINISHING WORK...1893
12.19 STOPPING ENGINE...1894
12.20 CHECK AFTER STOPPING ENGINE...1895
12.21 LOCKING...1895
13. TRANSPORTATION...1896
13.1 TRANSPORTATION PROCEDURE...1896
13.2 LOADING, UNLOADING WORK WITH TRAILERS...1897
13.3 METHOD OF LIFTING MACHINE...1903
14. COLD WEATHER OPERATION...1904
14.1 PRECAUTIONS FOR LOW TEMPERATURE...1904
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...1906
14.3 AFTER COLD WEATHER...1906
15. LONG-TERM STORAGE...1907
15.1 BEFORE STORAGE...1907
15.2 DURING STORAGE...1908
15.3 AFTER STORAGE...1908
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE...1908
16. TROUBLESHOOTING...1909
16.1 PHENOMENA THAT ARE NOT FAILURES...1909
16.2 METHOD OF TOWING MACHINE...1909
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE AM091120...1909
16.4 PRECAUTIONS ON PARTICULAR JOBSITES...1910
16.5 IF BATTERY IS DISCHARGED...1910
16.6 OTHER TROUBLE...1915
MAINTENANCE...1920
17. GUIDES TO MAINTENANCE...1921
18. OUTLINES OF SERVICE...1924
18.1 OUTLINE OF OIL, FUEL, COOLANT...1924
18.2 OUTLINE OF ELECTRIC SYSTEM...1927
18.3 OUTLINE OF HYDRAULIC SYSTEM...1928
19. WEAR PARTS LIST...1929
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...1931
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...1935
21.1 INTRODUCTION OF NECESSARY TOOLS...1935
21.2 TORQUE LIST...1936
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1937
23. MAINTENANCE SCHEDULE CHART...1939
23.1 MAINTENANCE SCHEDULE CHART...1939
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER...1941
24. SERVICE PROCEDURE...1942
24.1 INITIAL 250 HOURS SERVICE...1942
24.2 WHEN REQUIRED...1943
24.3 CHECK BEFORE STARTING...1961
24.4 EVERY 50 HOURS SERVICE...1965
24.5 EVERY 100 HOURS SERVICE...1967
24.6 EVERY 250 HOURS SERVICE...1969
24.7 EVERY 500 HOURS SERVICE...1976
24.8 EVERY 1000 HOURS SERVICE...1984
24.9 EVERY 2000 HOURS SERVICE...1987
24.10 EVERY 4000 HOURS SERVICE...1993
24.11 EVERY 5000 HOURS SERVICE...1994
SPECIFICATIONS...1996
25. SPECIFICATIONS...1997
OPTIONS, ATTACHMENTS...2004
26. GENERAL PRECAUTIONS...2005
26.1 PRECAUTIONS RELATED TO SAFETY...2005
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS...2006
27. HANDLING BUCKET WITH HOOK...2007
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...2007
27.2 PROHIBITED OPERATIONS...2007
27.3 PRECAUTIONS DURING OPERATIONS...2007
28. USING SEAT BELT...2008
28.1 SEAT BELT...2008
29. HANDLING CAR HEATER...2010
29.1 GENERAL LOCATIONS...2010
29.2 PREPARATION FOR CAR HEATER...2011
30. MACHINES READY FOR ATTACHMENT...2012
30.1 GENERAL LOCATIONS...2012
30.2 HYDRAULIC CIRCUIT...2014
30.3 PROCEDURE FOR REMOVAL AND INSTALLATION OF ATTACHMENT...2016
30.4 OPERATION...2018
30.5 LONG TERM STORAGE...2019
30.6 SPECIFICATIONS...2019
31. INTRODUCTION OF ATTACHMENTS...2020
31.1 SPECIFICATION, USE...2020
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE...2022
31.3 SELECTION OF TRACK SHOES...2024
31.4 SELECTION OF BUCKET TEETH...2025
31.5 HANDLING TRAPEZOIDAL BUCKET...2026
32. EXTENDING MACHINE SERVICE LIFE...2027
32.1 HYDRAULIC BREAKER...2027
32.2 POWER RIPPER...2031
32.3 FORK GRAB...2032
32.4 GRAPPLE BUCKET...2033
32.5 SCRAP GRAPPLE...2034
32.6 CRUSHER AND CUTTER...2035
32.7 HYDRAULIC PILE DRIVER...2036
32.8 HYDRAULIC EXCAVATOR WITH MULTI- PURPOSE CRANE...2037
33. AUTO-GREASING SYSTEM...2038
33.1 AUTO-GREASING CONTROLLER...2038
33.2 ACTION WHEN ABNORMALITY OCCURS...2039
33.3 CHECK BEFORE STARTING...2040
33.4 EVERY 50 HOURS SERVICE...2042
SEAM009003T - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Operation & Maintenance Manual...2044
COVER...2044
1. FOREWORD...2045
2. SAFETY INFORMATION...2046
3. INTRODUCTION...2047
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...2048
5. CONTENTS...2049
SAFETY...2053
6. GENERAL PRECAUTIONS...2054
7. PRECAUTIONS DURING OPERATION...2063
7.1 BEFORE STARTING ENGINE...2063
7.2 AFTER STARTING ENGINE...2065
7.3 TRANSPORTATION...2073
7.4 BATTERY...2075
7.5 TOWING...2077
7.6 BUCKET WITH HOOK...2078
8. PRECAUTIONS FOR MAINTENANCE...2079
8.1 BEFORE CARRYING OUT MAINTENANCE...2079
8.2 DURING MAINTENANCE...2084
9. POSITION FOR ATTACHING SAFETY LABELS...2091
OPERATION...2096
10. GENERAL VIEW...2097
10.1 GENERAL VIEW OF MACHINE...2097
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...2098
11. EXPLANATION OF COMPONENTS...2099
11.1 MACHINE MONITOR...2099
11.2 SWITCHES...2110
11.3 CONTROL LEVERS AND PEDALS...2114
11.4 CEILING WINDOW...2119
11.5 FRONT WINDOW...2120
11.6 DOOR LOCK...2122
11.7 CAP,COVER WITH LOCK...2123
11.8 HOT AND COOL BOX...2124
11.9 LUGGAGE BOX...2124
11.10 ASHTRAY...2124
11.11 HANDLING AIR CONDITIONER...2125
11.12 CAR RADIO...2128
11.13 ELECTRIC POWER TAKE-OUT ADAPTER...2132
11.14 FUSE...2133
11.15 FUSIBLE LINK...2134
11.16 CONTROLLERS...2134
11.17 TOOL BOX...2134
11.18 GREASE GUN HOLDER...2134
11.19 HANDLING ACCUMULATOR...2135
12. OPERATION...2136
12.1 CHECK BEFORE STARTING ENGINE...2136
12.2 STARTING ENGINE...2147
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...2150
12.4 MOVING MACHINE OFF...2156
12.5 STEERING MACHINE...2159
12.6 STOPPING MACHINE...2161
12.7 SWINGING...2162
12.8 OPERATION OF WORK EQUIPMENT...2163
12.9 HANDLING ACTIVE MODE...2164
12.10 HANDLING WORKING MODE...2165
12.11 PROHIBITIONS FOR OPERATION...2167
12.12 PRECAUTIONS FOR OPERATION...2169
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...2170
12.14 HOW TO ESCAPE FROM MUD...2172
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...2173
12.16 REPLACEMENT AND INVERSION OF BUCKET...2174
12.17 PARKING MACHINE...2176
12.18 CHECK AFTER FINISHING WORK...2177
12.19 STOPPING ENGINE...2178
12.20 CHECK AFTER STOPPING ENGINE...2179
12.21 LOCKING...2179
13. TRANSPORTATION...2180
13.1 TRANSPORTATION PROCEDURE...2180
13.2 LOADING,UNLOADING WORK WITH TRAILERS...2181
13.3 METHOD OF LIFTING MACHINE...2187
14. COLD WEATHER OPERATION...2188
14.1 PRECAUTIONS FOR LOW TEMPERATURE...2188
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...2190
14.3 AFTER COLD WEATHER...2190
15. LONG-TERM STORAGE...2191
15.1 BEFORE STORAGE...2191
15.2 DURING STORAGE...2192
15.3 AFTER STORAGE...2192
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE...2192
16. TROUBLESHOOTING...2193
16.1 PHENOMENA THAT ARE NOT FAILURES...2193
16.2 METHOD OF TOWING MACHINE...2193
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE...2193
16.4 PRECAUTIONS ON PARTICULAR JOBSITES...2194
16.5 IF BATTERY IS DISCHARGED...2194
16.6 OTHER TROUBLE...2199
MAINTENANCE...2204
17. GUIDES TO MAINTENANCE...2205
18. OUTLINES OF SERVICE...2208
18.1 OUTLINE OF OIL,FUEL,COOLANT...2208
18.2 OUTLINE OF ELECTRIC SYSTEM...2211
18.3 OUTLINE OF HYDRAULIC SYSTEM...2212
19. WEAR PARTS LIST...2213
20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...2215
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...2219
21.1 INTRODUCTION OF NECESSARY TOOLS...2219
21.2 TORQUE LIST...2220
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2221
23. MAINTENANCE SCHEDULE CHART...2223
23.1 MAINTENANCE SCHEDULE CHART...2223
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER...2225
24. SERVICE PROCEDURE...2226
24.1 INITIAL 250 HOURS SERVICE...2226
24.2 WHEN REQUIRED...2227
24.3 CHECK BEFORE STARTING...2245
24.4 EVERY 50 HOURS SERVICE...2249
24.5 EVERY 100 HOURS SERVICE...2251
24.6 EVERY 250 HOURS SERVICE...2253
24.7 EVERY 500 HOURS SERVICE...2260
24.8 EVERY 1000 HOURS SERVICE...2268
24.9 EVERY 2000 HOURS SERVICE...2271
24.10 EVERY 4000 HOURS SERVICE...2277
SPECIFICATIONS...2280
25. SPECIFICATIONS...2281
OPTIONS,ATTACHMENTS...2287
26. GENERAL PRECAUTIONS...2288
26.1 PRECAUTIONS RELATED TO SAFETY...2288
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS...2289
27. HANDLING BUCKET WITH HOOK...2290
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...2290
27.2 PROHIBITED OPERATIONS...2290
27.3 PRECAUTIONS DURING OPERATIONS...2290
28. USING SEAT BELT...2291
28.1 SEAT BELT...2291
29. HANDLING CAR HEATER...2293
29.1 GENERAL LOCATIONS...2293
29.2 PREPARATION FOR CAR HEATER...2294
30. MACHINES READY FOR ATTACHMENT...2295
30.1 GENERAL LOCATIONS...2295
30.2 HYDRAULIC CIRCUIT...2297
30.3 PROCEDURE FOR REMOVAL AND INSTALLATION OF ATTACHMENT...2299
30.4 OPERATION...2301
30.5 LONG TERM STORAGE...2302
30.6 SPECIFICATIONS...2302
31. INTRODUCTION OF ATTACHMENTS...2303
31.1 SPECIFICATION,USE...2303
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE...2305
31.3 SELECTION OF TRACK SHOES...2307
31.4 SELECTION OF BUCKET TEETH...2308
31.5 HANDLING TRAPEZOIDAL BUCKET...2309
32. EXTENDING MACHINE SERVICE LIFE...2310
32.1 HYDRAULIC BREAKER...2310
32.2 POWER RIPPER...2314
32.3 FORK GRAB...2315
32.4 GRAPPLE BUCKET...2316
32.5 SCRAP GRAPPLE...2317
32.6 CRUSHER AND CUTTER...2318
32.7 HYDRAULIC PILE DRIVER...2319
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE...2320
33. AUTO-GREASING SYSTEM...2321
33.1 AUTO GREASING CONTROLLER...2321
33.2 ACTION WHEN ABNORMALITY OCCURS...2322
33.3 CHECK BEFORE STARTING...2323
33.4 EVERY 50 HOURS SERVICE...2325
SEAM046000T - Hydraulic Excavator GALEO PC300-7, PC300LC-7, PC350-7, PC350LC-7 Operation & Maintenance Manual...2327
COVER...2327
FOREWORD...2328
FOREWORD...2329
SAFETY INFORMATION...2332
INTRODUCTION...2334
DIRECTIONS OF MACHINE...2334
PRODUCT INFORMATION...2335
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION...2335
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...2335
SERVICE METER LOCATION...2336
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...2336
CONTENTS...2337
SAFETY...2342
SAFETY INFORMATION...2343
POSITION FOR ATTACHING SAFETY LABELS...2345
POSITION FOR ATTACHING SAFETY LABELS...2345
SAFETY LABELS...2346
SAFETY INFORMATION...2351
SAFETY RULES...2351
IF ABNORMALITIES ARE FOUND...2351
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...2351
FIRE EXTINGUISHER AND FIRST AID KIT...2351
SAFETY EQUIPMENT...2352
KEEP MACHINE CLEAN...2352
KEEP OPERATOR'S COMPARTMENT CLEAN...2352
LEAVING OPERATOR'S SEAT WITH LOCK...2352
HANDRAILS AND STEPS...2353
MOUNTING AND DISMOUNTING...2354
NO PERSONS ON ATTACHMENTS...2354
BURN PREVENTION...2354
FIRE PREVENTION AND EXPLOSION PREVENTION...2355
ACTION IF FIRE OCCURS...2356
WINDSHIELD WASHER FLUID...2356
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...2356
ATTACHMENT INSTALLATION...2356
ATTACHMENT COMBINATIONS...2357
CAB WINDOW GLASSES...2357
UNAUTHORIZED MODIFICATIONS...2357
SAFETY AT JOBSITE...2357
WORKING ON LOOSE GROUND...2357
DISTANCE TO HIGH VOLTAGE CABLES...2358
ENSURE GOOD VISIBILITY...2358
VENTILATION FOR ENCLOSED AREA...2359
SIGNALMAN'S SIGNAL AND SIGNS...2359
EMERGENCY EXIT FROM OPERATOR'S CAB...2359
ASBESTOS DUST HAZARD PREVENTION...2359
SAFETY MACHINE OPERATION...2360
STARTING ENGINE...2360
CHECKS BEFORE STARTING ENGINE...2360
SAFETY RULES FOR STARTING ENGINE...2361
STARTING ENGINE IN COLD WEATHER...2361
OPERATION...2362
CHECKS AFTER STARTING ENGINE...2362
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...2362
SAFETY RULES FOR TRAVELING...2363
TRAVELING ON SLOPES...2364
OPERATIONS ON SLOPES...2365
PROHIBITED OPERATIONS...2365
OPERATIONS ON SNOW...2367
PARKING MACHINE...2367
TRANSPORTATION...2368
SHIPPING THE MACHINE...2368
BATTERY...2369
BATTERY HAZARD PREVENTION...2369
STARTING ENGINE WITH BOOSTER CABLES...2370
TOWING...2371
SAFETY RULES FOR TOWING...2371
LIFTING OBJECTS WITH BUCKET...2372
SAFETY RULES FOR LIFTING OBJECTS...2372
SAFETY MAINTENANCE INFORMATION...2373
WARNING TAG...2373
KEEP WORK PLACE CLEAN AND TIDY...2373
APPOINT LEADER WHEN WORKING WITH OTHERS...2373
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...2374
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...2375
PROPER TOOLS...2375
ACCUMULATOR...2376
PERSONNEL...2376
ATTACHMENTS...2376
WORK UNDER THE MACHINE...2376
NOISE...2377
WHEN USING HAMMER...2377
WELDING WORKS...2377
REMOVING BATTERY TERMINALS...2377
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...2378
DO NOT DISASSEMBLE RECOIL SPRINGS...2378
SAFETY RULES FOR HIGH-PRESSURE OIL...2378
SAFETY HANDLING HIGH-PRESSURE HOSES...2379
WASTE MATERIALS...2379
AIR CONDITIONER MAINTENANCE...2379
COMPRESSED AIR...2379
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2380
OPERATION...2381
GENERAL VIEW...2382
GENERAL VIEW OF MACHINE...2382
GENERAL VIEW CONTROLS AND GAUGES...2383
EXPLANATION OF COMPONENTS...2384
MACHINE MONITOR...2384
BASIC CHECK ITEMS...2385
SWITCHES...2397
CONTROL LEVERS, PEDALS...2403
CEILING WINDOW...2406
FRONT WINDOW...2407
EMERGENCY EXIT FROM OPERATOR'S CAB...2412
DOOR LOCK...2412
CAP, COVER WITH LOCK...2413
HOT AND COOL BOX...2414
MAGAZINE BOX...2414
ASHTRAY...2414
HANDLING AIR CONDITIONER...2415
CAR RADIO...2429
FUSE...2435
FUSIBLELINK...2436
CONTROLLER(COMPUTER)...2437
TOOLBOX...2437
GREASE GUN HOLDER...2437
HANDLING ACCUMULATOR...2438
MACHINE OPERATIONS AND CONTROLS...2439
BEFORE STARTING ENGINE...2439
STARTING ENGINE...2452
AFTER STARTING ENGINE...2456
IN COLD AREAS(AUTOMATIC WARMING-UP OPERATION)...2459
STOPPING THE ENGINE...2462
CHECK AFTER SHUT OFF ENGINE...2462
MACHINE OPERATION...2463
STEERING THE MACHINE...2467
SWINGING...2469
WORK EQUIPMENT CONTROLS AND OPERATIONS...2470
OPERATING WORKING MODE...2472
PROHIBITED OPERATIONS...2473
GENERAL OPERATION INFORMATION...2475
TRAVELING ON SLOPES...2476
ESCAPE FROM MUD...2478
RECOMMENDED APPLICATIONS...2479
REPLACEMENT AND INVERSION OF BUCKET...2481
PARKING MACHINE...2485
CHECK AFTER FINISHING WORK...2486
LOCKING...2487
TRANSPORTATION...2488
TRANSPORTATION PROCEDURE...2488
LOADING AND UNLOADING WITH TRAILER...2489
LIFTING MACHINE...2496
COLD WEATHER OPERATION...2498
COLD WEATHER OPERATION INFORMATION...2498
AFTER DAILY WORK COMPLETION...2500
AFTER COLD WEATHER SEASON...2501
LONG TERM STORAGE...2502
BEFORE STORAGE...2502
DURING STORAGE...2502
AFTER STORAGE...2503
TROUBLESHOOTING...2504
AFTER RUNNING OUT OF FUEL...2504
PHENOMENA THAT ARE NOT FAILURES...2504
TOWING THE MACHINE...2505
LIGHTWEIGHT TOWING HOOK...2505
PRECAUTIONS ON PARTICULAR JOBSITES...2506
DISCHARGED BATTERY...2507
OTHER TROUBLE...2511
MAINTENANCE...2516
MAINTENANCE INFORMATION...2517
LUBRICANTS, COOLANT AND FILTERS...2520
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...2520
ELECTRIC SYSTEM MAINTENANCE...2523
HANDLING HYDRAULIC SYSTEM...2523
WEAR PARTS LIST...2525
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...2526
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...2526
TIGHTENING TORQUE SPECIFICATIONS...2530
TIGHTENING TORQUE LIST...2530
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2531
SAFETY CRITICAL PARTS...2532
MAINTENANCE SCHEDULE...2533
MAINTENANCE SCHEDULE CHART...2533
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...2536
MAINTENANCE PROCEDURE...2537
INITIAL 250 HOURS MAINTENANCE(ONLY AFTER THE FIRST 250 HOURS)...2537
INITIAL 1000 HOURS MAINTENANCE(ONLY AFTER THE FIRST 1000 HOURS)...2537
WHEN REQUIRED...2538
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...2538
CLEAN INSIDE OF COOLING SYSTEM...2543
CHECK AND TIGHTEN TRACK SHOE BOLTS...2546
CHECK AND ADJUST TRACK TENSION...2547
CHECK ELECTRICAL INTAKE AIR HEATER...2549
REPLACE BUCKET TEETH(VERTICAL PIN TYPE)...2550
REPLACE BUCKET TEETH(HORIZONTAL PIN TYPE)...2553
REPLACE BUCKET SIDE CUTTER, SHROUD...2554
ADJUST BUCKET CLEARANCE...2555
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...2556
CHECK AND ADJUST AIR CONDITIONER(ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)...2557
WASHING WASHABLE FLOOR...2558
METHOD OF SETTING MACHINE ANGLE...2560
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...2563
CHECK BEFORE STARTING...2564
EVERY 50 HOURS MAINTENANCE...2565
LUBRICATING...2565
EVERY 100 HOURS MAINTENANCE...2566
LUBRICATING...2566
EVERY 250 HOURS MAINTENANCE...2568
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...2568
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...2569
CHECK LEVEL OF BATTERY ELECTROLYTE...2570
LUBRICATE SWING CIRCLE(2 POINTS)...2572
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...2573
EVERY 500 HOURS MAINTENANCE...2574
REPLACE FUEL FILTER CARTRIDGE...2574
CHECK SWING PINION GREASE LEVEL, ADD GREASE...2575
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...2576
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS...2578
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM...2579
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...2581
EVERY 1000 HOURS MAINTENANCE...2582
REPLACE HYDRAULIC FILTER ELEMENT...2582
CHANGE OIL IN SWING MACHINERY CASE...2584
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...2585
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...2585
CHECK PLAY OF TURBOCHARGER ROTOR...2585
REPLACE CORROSION RESISTOR CARTRIDGE...2585
CHECK FAN BELT TENSION AND REPLACE FAN BELT...2586
EVERY 2000 HOURS MAINTENANCE...2587
CHANGE OIL IN FINAL DRIVE CASE...2587
CLEAN HYDRAULIC TANK STRAINER...2588
CLEAN ENGINE BREATHER...2588
CLEAN, CHECK TURBOCHARGER...2589
CHECK ALTERNATOR, STARTING MOTOR...2589
CHECK ENGINE VALVE CLEARANCE, ADJUST...2589
CHECK VIBRATION DAMPER...2589
EVERY 4000 HOURS MAINTENENCE...2590
CHECK WATER PUMP...2590
EVERY 5000 HOURS MAINTENANCE...2591
CHANGE OIL IN HYDRAULIC TANK...2591
SPECIFICATIONS...2592
SPECIFICATIONS...2593
ATTACHMENTS AND OPTIONS...2595
GENERAL PRECAUTIONS...2596
PRECAUTIONS RELATED TO SAFETY...2596
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...2598
HANDLING BUCKET WITH HOOK...2599
CHECKING FOR DAMAGE TO BUCKET WITH HOOK...2599
PROHIBITED OPERATIONS...2599
MACHINES READY FOR ATTACHMENTS...2600
EXPLANATION OF COMPONENTS...2600
HYDRAULIC CIRCUIT...2603
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...2607
OPERATION...2609
LONG-TERM STORAGE...2611
SPECIFICATIONS...2611
HANDLING SCSH BUSHING...2612
EVERY 250 HOURS MAINTENANCE...2612
EVERY 500 HOURS MAINTENANCE...2613
ATTACHMENT GUIDE...2615
COMBINATIONS OF WORK EQUIPMENT...2615
RECOMMENDED ATTACHMENT OPERATIONS...2617
HYDRAULIC BREAKER...2617
MULTI-MONITOR SPECIFICATION...2622
CONTENTS...2623
GENERAL VIEW...2624
GENERAL VIEW CONTROLS AND GAUGES...2624
EXPLANATION OF COMPONENTS...2625
MACHINE MONITOR...2625
BASIC CHECK ITEMS...2628
MACHINE OPERATIONS AND CONTROLS...2649
BEFORE STARTING ENGINE...2649
STARTING ENGINE...2652
AFTER STARTING ENGINE...2656
IN COLD AREAS(AUTOMATIC WARMING-UP OPERATION)...2660
MACHINE OPERATION...2664
SWINGING...2667
OPERATING WORKING MODE...2668
GENERAL OPERATION INFORMATION...2669
CHECK AFTER FINISHING WORK...2670
TRANSPORTATION...2671
TRANSPORTATION PROCEDURE...2671
LOADING AND UNLOADING WITH TRAILER...2672
MAINTENANCE PROCEDURE...2679
WHEN REQUIRED...2679
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...2679
INDEX...2684
SEBM006603 - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Shop Manual...2687
COVER...2687
CONTENTS...2688
01 GENERAL...2706
SPECIFICATION DRAWINGS...2707
SPECIFICATIONS...2709
WEIGHT TABLE...2713
FUEL, COOLANT AND LUBRICANTS...2717
10 STRUCTURE AND FUNCTION...2719
PARTS RELATED TO ENGINE...2720
RADIATOR, OIL COOLER...2722
POWER TRAIN...2723
FINAL DRIVE...2724
SWING CIRCLE...2725
SWING MACHINERY...2726
TRACK FRAME, RECOIL SPRING...2727
TRACK SHOE...2728
HYDRAULIC PIPING DRAWING...2729
HYDRAULIC CIRCUIT DRAWING...2730
HYDRAULIC TANK, HYDRAULIC FILTER...2731
HYDRAULIC PUMP...2732
CONTROL VALVE...2753
SUCTION SAFETY VALVE...2762
CLSS...2763
SWING MOTOR...2805
CENTER SWIVEL JOINT...2809
TRAVEL MOTOR...2810
VALVE CONTROL...2819
WORK EQUIPMENT, SWING PPC VALVE...2820
TRAVEL PPC VALVE...2824
SERVICE PPC VALVE...2828
PPC SAFETY LOCK VALVE...2831
PPC ACCUMULATOR...2831
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE...2832
EPC SOLENOID VALVE...2839
FOR LS SELECT, BOOM HI 2-STAGE SAFETY VALVE, MERGE/FLOW DIVIDER, TRAVEL SPEED, SWING BRAKE...2839
FOR LS VALVE CONTROL...2841
BOOM HOLDING VALVE...2844
HYDRAULIC CYLINDER...2847
WORK EQUIPMENT...2848
ACTUAL ELECTRIC WIRING DIAGRAM...2849
ELECTRIC CIRCUIT DIAGRAM...2851
ENGINE CONTROL ...2854
ELECTRONIC CONTROL SYSTEM...2860
MACHINE MONITOR SYSTEM...2883
FRONT WINDOW AUTO PULL-UP SYSTEM...2890
20 TESTING AND ADJUSTING...2892
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...2893
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...2894
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...2902
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...2910
MEASURING ENGINE SPEED...2911
MEASURING EXHAUST COLOR...2912
ADJUSTING VALVE CLEARANCE...2913
MEASURING COMPRESSION PRESSURE...2914
MEASURING BLOW-BY PRESSURE...2914
TESTING AND ADJUSTING FUEL INJECTION TIMING...2915
MEASURING ENGINE OIL PRESSURE...2916
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...2917
TESTING AND ADJUSTING WATER PUMP BELT TENSION...2917
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...2918
ADJUSTING ENGINE SPEED SENSOR...2918
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...2919
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE...2920
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...2921
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...2924
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE...2926
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE...2929
TESTING SOLENOID VALVE OUTPUT PRESSURE...2931
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...2933
ADJUSTING WORK EQUIPMENT,SWING PPC VALVE...2935
TESTING TRAVEL DEVIATION...2936
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...2937
MEASURING OIL LEAKAGE...2939
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...2941
TESTING CLEARANCE OF SWING CIRCLE BEARING...2942
TESTING AND ADJUSTING TRACK SHOE TENSION...2943
BLEEDING AIR...2944
TROUBLESHOOTING...2946
POINTS TO REMEMBER WHEN TROUBLESHOOTING...2947
SEQUENCE OF EVENTS IN TROUBLESHOOTING...2948
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...2949
CHECKS BEFORE TROUBLESHOOTING...2957
CONNECTOR TYPES AND MOUNTING LOCATIONS...2958
CONNECTOR ARRANGEMENT DIAGRAM...2960
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2962
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...2972
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...2973
METHOD OF USING JUDGEMENT TABLE...2981
METHOD OF USING TROUBLESHOOTING CHARTS...2983
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...2985
SERVICE CODE TABLE...2990
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)...2991
N-1 [E218] COMMUNICATION ABNORMALITY...2992
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)...2994
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM...2995
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...2996
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS...3000
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM...3002
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)...3004
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED...3005
E-3 [E317] ABNORMALITY (DISCONNECTION) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED...3006
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED...3007
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...3008
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED...3009
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED...3010
E-8 ENGINE DOES NOT START...3011
E-9 ENGINE SPEED IS IRREGULAR...3013
a) IDLING SPEED IS IRREGULAR...3013
b) THERE IS HUNTING...3015
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)...3017
E-11 ENGINE DOES NOT STOP...3019
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)...3021
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...3023
METHOD OF USING TROUBLESHOOTING CHARTS...3024
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...3028
S-2 ENGINE DOES NOT START...3029
(1) ENGINE DOES NOT TURN...3029
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...3030
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...3031
S-3 ENGINE DOES NOT PICK UP SMOOTHLY...3032
S-4 ENGINE STOPS DURING OPERATIONS...3033
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...3034
S-6 ENGINE LACKS OUTPUT (NO POWER)...3035
S-7 EXHAUST SOMKE IS BLACK...3036
S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST SMOKE IS BLUE...3037
S-9 OIL BECOMES CONTAMINATED QUICKLY...3038
S-10 FUEL CONSUMPTION IS EXCESSIVE...3039
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...3040
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...3041
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...3042
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...3043
S-15 ABNORMAL NOISE IS MADE...3044
S-16 VIBRATION IS EXCESSIVE...3045
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)...3046
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...3047
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...3048
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS...3054
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE...3056
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)...3058
C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED...3059
C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED...3061
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED...3063
C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED...3065
C-6 [E202] SHORT CIRCUIT IN LS SELECT SOLENOID SYSTEM IS DISPLAYED...3067
C-7 [E212] DISCONNECTION IN LS SELECT SOLENOID SYSTEM IS DISPLAYED...3068
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...3069
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...3071
C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED...3073
C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED...3074
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IN DISPLAYED...3075
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED...3076
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED...3077
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED...3079
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED...3080
C-17 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...3081
C-18 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...3082
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED...3083
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...3084
C-21 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)...3085
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)...3087
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE...3088
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...3090
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP...3091
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP...3092
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP...3093
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP...3094
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...3095
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...3096
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP...3097
F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP...3098
F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP...3099
F-11 BIT PATTERN 22-(6) L. H. KNOB SWITCH DOES NOT LIGHT UP...3100
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...3101
PUMP MERGE/DIVIDER LOGIC, LS SELECT LOGIC, SOLENOID ACTUATION TABLE...3102
TABLE OF FAILURE MODES AND CAUSES...3103
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...3107
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...3109
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...3110
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)...3110
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)...3111
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...3111
H-7 BOOM IS SLOW OR LACKS POWER...3112
H-8 ARM IS SLOW OR LACKS POWER...3114
H-9 BUCKET IS SLOW OR LACKS POWER...3116
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)...3117
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...3117
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...3118
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED...3118
H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED...3119
H-15 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION...3119
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW...3119
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...3120
H-18 IN SWING + ARM, ARM IS SLOW...3120
H-19 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY...3120
H-20 TRAVEL DEVIATION...3121
H-21 TRAVEL SPEED IS SLOW...3122
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER...3124
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SET SPEED...3126
H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...3126
H-25 DOES NOT SWING...3127
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW...3128
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING...3130
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)...3131
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...3131
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING...3132
H-31 SWING SPEED IS FASTER THAN SPECIFIED SPEED...3133
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...3134
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...3136
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM...3138
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED.[E102] ERROR IN CLOCK DATA IS DISPLAYED...3140
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED...3141
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED...3142
M-4 [E106] DROP IN ENGINE OIL PRESSURE HI PRESSURE DETECTED IS DISPLAYED...3142
M-5 [E108] ENGINE WATER TEMPERATURE 105℃ DETECTED IS DISPLAYED...3143
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS...3144
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT...3146
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)...3146
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES...3147
M-10 PREHEATING IS NOT BEING USED BUT PREHEATING MONITOR LIGHTS UP...3150
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH...3151
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY,ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)...3153
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)...3155
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPER), BUZZER DOES NOT SOUND FOR 1 SECOND.CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND...3158
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS...3158
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)...3159
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE...3160
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)...3160
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL...3161
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY...3161
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT SWING LOCK MONITOR DOES NOT LIGHT UP...3162
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH...3162
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING ...3163
M-24 WHEN STARING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED...3163
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM...3164
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM...3165
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM...3166
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM...3167
M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM...3168
M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED...3169
M-31 ELECTRIC GREASE GUN DOES NOT WORK...3173
30 DISASSEMBLY AND ASSEMBLY...3174
METHOD OF USING MANUAL...3176
PRECAUTIONS WHEN CARRYING OUT OPERATION...3178
SPECIAL TOOL LIST...3180
SKETCHES OF SPECIAL TOOLS...3185
STARTING MOTOR ASSEMBLY...3190
REMOVAL AND INSTALLATION...3190
ALTERNATOR ASSEMBLY...3191
REMOVAL AND INSTALLATION...3191
ENGINE OIL COOLER ASSEMBLY...3192
REMOVAL AND INSTALLATION...3192
FUEL INJECTION PUMP ASSEMBLY...3193
REMOVAL...3193
INSTALLATION...3194
WATER PUMP ASSEMBLY...3195
REMOVAL AND INSTALLATION...3195
NOZZLE HOLDER ASSEMBLY...3196
REMOVAL AND INSTALLATION...3196
TURBOCHARGER ASSEMBLY...3197
REMOVAL AND INSTALLATION...3197
THERMOSTAT ASSEMBLY...3198
REMOVAL AND INSTALLATION...3198
ENGINE FRONT SEAL...3199
REMOVAL...3199
INSTALLATION...3200
GOVERNOR MOTOR ASSEMBLY...3201
REMOVAL AND INSTALLATION...3201
CYLINDER HEAD ASSEMBLY...3202
REMOVAL...3202
INSTALLATION...3204
AFTERCOOLER ASSEMBLY...3207
REMOVAL AND INSTALLATION...3207
HYDRAULIC COOLER ASSEMBLY...3208
REMOVAL AND INSTALLATION...3208
RADIATOR, HYDRAULIC COOLER ASSEMBLY...3209
REMOVAL...3209
INSTALLATION...3210
ENGINE, MAIN PUMP ASSEMBLY...3211
REMOVAL...3211
INSTALLATION...3213
DAMPER ASSEMBLY...3214
REMOVAL AND INSTALLATION...3214
FUEL TANK ASSEMBLY...3215
REMOVAL AND INSTALLATION...3215
CENTER SWIVEL JOINT ASSEMBLY...3216
REMOVAL AND INSTALLATION...3216
DISASSEMBLY AND ASSEMBLY...3217
FINAL DRIVE ASSEMBLY...3218
REMOVAL AND INSTALLATION...3218
DISASSEMBLY ...3219
ASSEMBLY...3223
TRAVEL MOTOR ASSEMBLY...3229
DISASSEMBLY...3229
ASSEMBLY...3234
SPROCKET...3243
REMOVAL AND INSTALLATION...3243
SWING MOTOR ASSEMBLY...3244
REMOVAL AND INSTALLATION...3244
DISASSEMBLY...3245
ASSEMBLY...3248
SWING MACHINERY ASSEMBLY...3255
REMOVAL AND INSTALLATION...3255
DISASSEMBLY...3256
ASSEMBLY...3260
REVOLVING FRAME ASSEMBLY...3265
REMOVAL...3265
INSTALLATION...3266
SWING CIRCLE ASSEMBLY...3267
REMOVAL AND INSTALLATION...3267
IDLER, RECOIL SPRING ASSEMBLY...3268
REMOVAL AND INSTALLATION...3268
IDLER ASSEMBLY...3269
DISASSEMBLY...3269
ASSEMBLY...3270
RECOIL SPRING ASSEMBLY...3272
DISASSEMBLY...3272
ASSEMBLY...3273
TRACK ROLLER ASSEMBLY...3274
REMOVAL AND INSTALLATION...3274
DISASSEMBLY...3275
ASSEMBLY...3276
CARRIER ROLLER ASSEMBLY...3278
REMOVAL AND INSTALLATION...3278
DISASSEMBLY...3279
ASSEMBLY...3281
TRACK SHOE ASSEMBLY...3283
REMOVAL AND INSTALLATION...3283
HYDRAULIC TANK ASSEMBLY...3284
REMOVAL...3284
INSTALLATION...3285
CONTROL PUMP ASSEMBLY...3286
REMOVAL AND INSTALLATION...3286
MAIN PUMP ASSEMBLY...3287
REMOVAL...3287
INSTALLATION...3288
DISASSEMBLY...3289
ASSEMBLY...3295
MAIN PUMP INPUT SHAFT OIL SEAL...3309
REMOVAL AND INSTALLATION...3309
CONTROL VALVE ASSEMBLY...3310
REMOVAL...3310
INSTALLATION...3312
DISASSEMBLY...3313
ASSEMBLY...3317
PUMP MERGE/DIVIDER VALVE ASSEMBLY...3322
DISASSEMBLY AND ASSEMBLY...3322
PRESSURE COMPENSATION VALVE ASSEMBLY...3323
DISASSEMBLY AND ASSEMBLY...3323
SERVO VALVE ASSEMBLY FOR FRONT PUMP...3324
REMOVAL AND INSTALLATION...3324
SERVO VALVE ASSEMBLY FOR REAR PUMP...3325
REMOVAL AND INSTALLATION...3325
LS-EPC SOLENOID VALVE ASSEMBLY...3326
REMOVAL AND INSTALLATION...3326
SOLENOID VALVE ASSEMBLY...3327
REMOVAL AND INSTALLATION...3327
WORK EQUIPMENT PPC VALVE ASSEMBLY...3328
REMOVAL AND INSTALLATION...3328
DISASSEMBLY...3329
ASSEMBLY...3330
TRAVEL PPC VALVE ASSEMBLY...3331
REMOVAL AND INSTALLATION...3331
DISASSEMBLY...3332
ASSEMBLY...3333
PPC SHUTTLE VALVE ASSEMBLY...3334
REMOVAL ...3334
INSTALLATION...3335
DISASSEMBLY...3336
ASSEMBLY...3337
BOOM LOCK VALVE ASSEMBLY...3338
REMOVAL AND INSTALLATION...3338
DISASSEMBLY AND ASSEMBLY...3339
BOOM CYLINDER ASSEMBLY...3340
REMOVAL ...3340
INSTALLATION...3341
ARM CYLINDER ASSEMBLY...3342
REMOVAL...3342
INSTALLATION...3343
BUCKET CYLINDER ASSEMBLY...3344
REMOVAL...3344
INSTALLATION...3345
HYDRAULIC CYLINDER ASSEMBLY...3346
DISASSEMBLY...3346
ASSEMBLY...3348
WORK EQUIPMENT ASSEMBLY...3350
REMOVAL...3350
INSTALLATION...3351
BUCKET ASSEMBLY...3352
REMOVAL...3352
INSTALLATION...3353
ARM ASSEMBLY...3354
REMOVAL ...3354
INSTALLATION...3355
BUCKET, ARM ASSEMBLY...3356
REMOVAL ...3356
INSTALLATION...3357
BOOM ASSEMBLY...3358
REMOVAL ...3358
INSTALLATION...3359
OPERATOR'S CAB ASSEMBLY...3360
REMOVAL...3360
INSTALLATION...3361
COUNTERWEIGHT ASSEMBLY...3362
REMOVAL AND INSTALLATION...3362
AIR CONDITIONER COMPRESSOR ASSEMBLY...3363
REMOVAL AND INSTALLATION...3363
CONDENSER ASSEMBLY...3364
REMOVAL AND INSTALLATION...3364
AIR CONDITIONER UNIT ASSEMBLY...3365
REMOVAL...3365
INSTALLATION...3366
GOVERNOR, PUMP CONTROLLER ASSEMBLY...3367
REMOVAL AND INSTALLATION...3367
MONITOR PANEL ASSEMBLY...3368
REMOVAL AND INSTALLATION...3368
CONTROL STAND CASE...3369
REMOVAL...3369
INSTALLATION...3370
40 MAINTENANCE STANDARD...3371
ENGINE MOUNT...3372
SWING MACHINERY...3373
SWING CIRCLE...3375
FINAL DRIVE...3376
TRACK FRAME AND RECOIL SPRING...3378
IDLER...3379
CARRIER ROLLER...3381
TRACK ROLLER...3382
TRACK...3383
HYDRAULIC PUMP...3385
CONTROL PUMP AND RELIEF VALVE...3386
CONTROL VALVE...3387
SUCTION-SAFETY VALVE...3393
SWING MOTOR...3394
TRAVEL MOTOR...3395
WORK EQUIPMENT, SWING PPC VALVE...3396
TRAVEL PPC VALVE...3397
SERVICE PPC VALVE...3398
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE...3399
EPC SOLENOID VALVE...3400
CENTER SWIVEL JOINT ...3401
BOOM HOLDING VALVE...3402
HYDRAULIC CYLINDER...3403
WORK EQUIPMENT ...3404
90 OTHERS...3410
HYDRAULIC PIPING DIAGRAM (10-12)...3411
HYDRAULIC CIRCUIT DIAGRAM (10-13)...3412
CONTROL VALVE...3413
10-SPOOL VALVE (10-38)...3413
9-SPOOL VALVE (10-44)...3414
8-SPOOL VALVE (10-45)...3415
7-SPOOL VALVE (10-46)...3416
OPERATION FOR EACH FUNCTION OF CLSS (10-52)...3417
OPERATION OF WHOLE CLSS SYSTEM...3418
1.WHEN ALL WORK EQUIPMENT IS AT NEUTRAL (10-72)...3418
2.PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY (10-74)...3419
3.PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY (10-76)...3420
4.PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY (10-78)...3421
5.PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY (10-80)...3422
6.PUMP FLOW DIVIDED, TRAVEL OPERATED INDEPENDENTLY (10-82)...3423
7.PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY (10-84)...3424
8.PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY (10-86)...3425
9.PUMP FLOW DIVIDED (PUMP PRESSURE:19.6 MPa (200kg/cm2) OR ABOVE), TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY (10-88)...3426
10.PUMP FLOW DIVIDED (PUMP PRESSURE:19.6 MPa (200 kg/cm2) OR ABOVE), TRAVEL + ARM IN OPERATED SIMULTANEOUSLY (10-90)...3427
ACTUAL ELECTRIC WIRING DIAGRAM (10-138)...3428
ACTUAL ELECTRIC WIRING DIAGRAM (10-139)...3429
ELECTRIC CIRCUIT DIAGRAM (10-140)...3430
ELECTRIC CIRCUIT DIAGRAM (10-141)...3431
CONNECTOR ARRANGEMENT DIAGRAM (20-116)...3432
CONTROL VALVE (40-20)...3433
SEBM014307 - Hydraulic Excavator PC300-6, PC300LC-6, PC350-6, PC350LC-6 Shop Manual...3434
COVER...3434
CONTENTS...3435
SAFETY...3441
FOREWARD...3443
HOW TO READ THE SHOP MANUAL...3444
HOISTING INSTRUCTIONS...3445
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...3446
COATING MATERIALS...3448
STANDARD TIGHENING TORQUE...3450
ELECTRIC WIRE CODE...3453
COVERSION TABLE...3454
01 GENERAL...3461
SPECIFICATION DRAWINGS...3462
SPECIFICATIONS...3464
WEIGHT TABLE...3468
FUEL, COOLANT AND LUBRICANTS...3472
10 STRUCTURE AND FUNCTION...3474
PARTS RELATED TO ENGINE...3475
RADIATOR, OIL COOLER...3477
POWER TRAIN...3478
FINAL DRIVE...3479
SWING CIRCLE...3480
SWING MACHINERY...3482
TRACK FRAME, RECIOL SPRING...3483
TRACK SHOE...3484
HYDRAULIC PIPING DRAWING...3485
HYDRAULIC CIRUIT DIAGRAM...3487
HYDRAULIC TANK, HYDRAULIC FILTER...3488
HYDRAULIC PUMP...3489
CONTROL VALVE...3508
SELF-REDUCING PRESSURE VALVE...3517
SUCTION SAFETY VALVE...3522
CLSS...3523
SWING MOTOR...3577
CENTER SWIVEL JOINT...3583
TRAVEL MOTOR...3585
VALVE CONTROL...3594
WORK EQUIPMENT - SWING PPC VALVE...3595
TRAVEL PPC VALVE...3599
SERVICE PPC VALVE...3603
PPC SAFETY LOCK VALVE...3606
PPC ACCUMULATOR...3606
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE...3607
LS-EPC VALVE ...3614
SOLENOID VALVE...3617
BOOM HOLDING VALVE...3619
WORK EQUIPMENT...3622
AIR CONDITIONER...3623
ACTUAL ELECTRICAL WIRING DIAGRAM...3624
ELECTRIC CIRCUIT DIAGRAM...3628
ENGINE CONTROL...3634
ELECTRONIC CONTROL SYSTEM...3640
MACHINE MONITOR SYSTEM...3665
FRONT WINDOW AUTO PULL-UP SYSTEM...3675
20 TESTING AND ADJUSTING...3677
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...3679
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...3680
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...3688
TESTING AND ADJUSTING...3696
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...3696
MEASURING ENGINE SPEED...3697
MEASURING EXHAUST COLOR...3698
ADJUSTING VALVE CLEARANCE...3699
MEASURING COMPRESSION PRESSURE...3700
MEASURING BLOW-BY PRESSURE...3700
TESTING AND ADJUSTING FUEL INJECTION TIMING...3701
MEASURING ENGINE OIL PRESSURE...3702
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...3703
TESTING AND ADJUSTING WATER PUMP BELT TENSION...3703
TESTING AND AJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...3704
ADJUSTING ENGINE SPEED...3704
MEASURING AIR SUPPLY (BOOST PRESSURE)...3705
TESTING AND AJUSTING GOVERNOR MOTOR LEVER STROKE...3706
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...3707
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...3711
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE DIFFERENTIAL PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSU...3714
TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED)...3719
TESTING SOLENOID VALVE OUTPUT PRESSURE...3720
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...3723
ADJUSTING WORK EQUIPMENT, SWING PC VALVE...3725
TESTING TRAVEL DEVIATION...3726
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...3727
MEASURING OIL LEAKAGE...3729
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT...3731
TESTING CLEARENCE OF SWING CIRCLE BEARING...3732
TESTING WEAR OF SPROCKET...3733
TESTING AND ADJUSTING TRACK SHOE TENSION...3734
BLEEDING AIR...3735
TROUBLESHOOTING...3737
POINTS TO REMEMBER WHEN TROUBLESHOOTING...3738
SEQUENCE OF EVENTS IN TROUBLESHOOTING...3739
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...3740
CHECKS BEFORE TROUBLESHOOTING...3748
CONNECTOR TYPES AND MOUNTING LOCATIONS...3749
CONNECTOR ARRANGEMENT DIAGRAM...3751
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...3754
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...3764
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...3765
METHOD OF USING JUDGEMENT TABLE...3774
METHOD OF USING TROUBLESHOOTING CHARTS...3776
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...3778
SERVICE CODE TABLE...3783
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)...3784
N-1 [E218] COMMUNICATION ABNORMALITY...3785
TROUBLESHOOTING OF OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)...3787
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM...3788
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...3789
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS...3793
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM...3795
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)...3797
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALVE IS DISPLAYED...3798
E-3 [E317] E-1 ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED...3799
E-4 [E318] E-1 ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED...3800
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...3801
E-6 [E315] ABNORMALITY (SHORT CIRCUIT IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED)...3802
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED...3803
E-8 ENGINE DOES NOT START...3804
E-9 ENGINE SPEED IS IRREGULAR...3806
A) IDLING SPEED IS IRREGULAR...3806
B) THERE IS HUNTING...3808
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)...3810
E-11 ENGINE DOES NOT STOP...3812
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)...3814
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...3816
METHOD OF USING TROUBLESHOOTING CHARTS...3817
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...3821
S-2 ENGINE DOES NOT START...3822
1) ENGINE DOES NOT TURN...3822
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...3823
3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...3824
S-3 ENGINE DOES NOT PICK UP SMOOTHLY...3825
S-4 ENGINE STOPS DURING OPERATION...3826
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...3827
S-6 ENGINE LACKS OUTPUT (NO POWER)...3828
S-7 EXHAUST GAS IS BLACK...3829
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...3830
S-9 OIL BECOMES CONTAMINATED QUICKLY...3831
S-10 FUEL CONSUMPTION IS EXCESSIVE...3832
S-11 OIL IS COOLING WATER, OR WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...3833
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...3834
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...3835
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...3836
S-15 ABNORMAL NOISE IS MADE...3837
S-16 VIBRATION IS EXCESSIVE...3838
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)...3839
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...3840
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...3841
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS...3849
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE...3851
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)...3853
C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED...3854
C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED...3856
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED...3858
C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED ...3860
C-6 [E207] SHORT CIRCUIT IN ACTION MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED...3862
C-7 [E208] DISCONNECTION IN ACTION MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED...3863
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...3864
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...3866
C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED...3868
C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED...3869
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...3870
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...3871
C-14 [E231] SHORT CIRCUIT IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED...3872
C-15 [E235] DISCONNECTION CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...3873
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED...3874
C-17 [E222] SHORT CIRCUIT IN ACC-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED ...3876
C-18 [E223] DISCONNECTION IN ACC-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED ...3877
C-19 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...3878
C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...3879
C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED...3880
C-22 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...3881
C-23 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)...3882
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)...3884
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE...3885
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...3887
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP...3888
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP...3889
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP...3890
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP...3891
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...3892
F-7 BIT PATTERN 20-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...3893
F-8 BIT PATTERN 20-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP...3894
F-9 BIT PATTERN 20-(3) SWING LOCK SWITCH DOES NOT LIGHT UP...3895
F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP...3896
F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP...3897
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...3898
PUMP MERGE/DIVIDER LOGIC, SOLENOID ACTUATION TABLE...3900
TABLE OF FAILURE MODES AND CAUSES...3901
ALL WORK EQUIPMENT, TRAVEL, SWING...3905
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...3905
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...3907
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...3908
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)...3908
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)...3909
H-6 FINE CONTROL ABILTY IS POOR RESPONSE IS POOR ...3909
WORK EQUIPMENT...3910
H-7 BOOM IS SLOW OR LACKS POWER...3910
H-8 ARM IS SLOW OR LACKS POWER...3912
H-9 BUCKET IS SLOW OR LACKS POWER...3914
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)...3915
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...3915
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...3916
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED...3916
H-14 IN L/O F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED...3917
H-15 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION...3917
COMPOUND OPERATIONS...3917
H-16 INCOMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW...3917
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...3918
H-18 IN SWING + ARM, ARM IS SLOW...3918
H-19 IN SWING + TRAVEL SPEED DROPS EXCESSIVELY...3918
TRAVEL SYSTEM...3919
H-20 TRAVEL DEVIATION...3919
A) WHEN THERE IS DEVIATION IN NORMAL TRAVEL...3919
B) EXCESSIVE TRAVEL DEVIATION WHEN STARTING...3919
H-21 TRAVEL SPEED IS SLOW...3920
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER...3922
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED...3924
H-24 TRAVEL DOES MOVE (ONE SIDE ONLY)...3924
SWING SYSTEM...3925
H-25 DOES NOT SWING...3925
A) DOES NOT SWING TO EITHER LEFT OR RIGHT...3925
B) DOES NOT SWING IN ONE DIRECTION...3925
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW (BLOW LEFT AND RIGHT, ONE DIRECTION ONLY)...3926
A) SWING ACCELERATIONS IS POOR...3926
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING...3928
A) ONE DIRECTION ONLY...3928
B) BOTH DIRECTIONS...3928
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)...3929
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING...3929
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING...3930
A) WHEN SWING HOLDING BRAKE IS RELEASED...3930
B) WHEN SWING HOLDING BRAKE IS APPLIED...3930
H-31 SWING SPEED IS FASTER THAN SPECIFIED SPEED...3931
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...3932
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...3934
ELECTRICAL CIRCUIT DIAGRAM M MODE SYSTEM ...3936
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED...3940
[E102] ERROR IN CLOCK DATA IS DISPLAYED...3940
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED ...3941
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED...3942
M-4 [E106] DROP IN ENGINE OIL PRESSURE HI DETECTED IS DISPLAYED...3942
M-5 [E108] ENGINE WATER TEMPERATURE 105 C DETECTED IS DISPLAYED...3943
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS...3944
A) NONE OF LAMP ON MONITOR PANEL LIGHT UP...3944
B) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP...3944
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT...3946
M-8 WHEN STARTING WITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAl MACHINE (MODEL)...3946
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH...3947
A) (COOLANT LEVEL) FLASHES...3947
B) (ENGINE OIL LEVEL) FLASHES...3948
C) (HYDRAULIC OIL LEVEL) FLASHES...3949
M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP...3950
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH...3951
A) ALTERNATOR SYSTEM...3951
B) ENGINE OIL PRESSURE SYSTEM...3952
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH...3953
A) ALTERNATOR SYSTEM...3953
B) ENGINE OIL PRESSURE SYSTEM...3954
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH...3955
A) (ENGINE OIL PRESSURE) FLASHES...3955
B) (COOLANT LEVEL) FLASHES...3955
C) (BATTERY CHARGE) FLASHES...3955
D) (COOLANT TEMPERATURE) FLASHES ...3956
E) (FUEL LEVEL) FLASHES...3956
F) (AIR CLEANER CLOGGING) FLASHES...3957
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER ...3958
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS...3958
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)...3959
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE...3960
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY...3960
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL...3961
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY...3961
M-21 SWING LOCK SWITCH IS TURNED ON LOCK SWITCH IS TURNED ON ...3962
M-22 SWING LOCK SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP...3962
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING...3963
M-24 WHEN STARTING SWITCH IS OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED...3963
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM...3964
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM...3965
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM...3966
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM...3967
M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM...3968
M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113)...3969
A) WIPER DOES NOT WORK...3969
B) WIPER SWITCH IS NOT BEING OPERATED BUT WIPER IS ACTUATED...3974
M-31 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114)...3975
A) WASHER MOTOR DOES NOT WORK...3975
B) SWITCH IS NOT BEING OPERATED BUT WASHER IS ACTUATED...3976
M-32 ELECTRIC GREASE GUN DOES NOT WORK...3978
30 DISASSEMBLY AND ASSEMBLY...3979
METHOD OF USING MANUAL...3981
PRECAUTIONS WHEN CARRYING OUT OPERATION...3983
SPECIAL TOOL LIST...3985
SKETCHES OF SPECIAL TOOLS...3990
STARTING MOTOR ASSEMBLY...3995
REMOVAL AND INSTALLATION...3995
ALTERNATOR ASSEMBLY...3996
REMOVAL AND INSTALLATION...3996
ENGINE OIL COOLER ASSEMBLY...3997
REMOVAL AND INSTALLATION...3997
FUEL INJECTION PUMP...3998
REMOVAL...3998
INSTALLATION...3999
WATER PUMP ASSEMBLY...4000
REMOVAL AND INSTALLATION...4000
NOZZLE HOLDER...4001
REMOVAL AND INSTALLATION...4001
TURBOCHARGER...4002
REMOVAL AND INSTALLATION...4002
THERMOSTAT...4003
REMOVAL AND INSTALLATION...4003
ENGINE FRONT SEAL...4004
REMOVAL ...4004
INSTALLATION...4005
ENGINE REAR SEAL...4006
REMOVAL...4006
INSTALLATION...4006
GOVERNOR MOTOR ASSEMBLY...4008
REMOVAL AND INSTALLATION...4008
CYLINDER HEAD ASSEMBLY...4009
REMOVAL...4009
INSTALLATION...4011
AFTERCOOLER ASSEMBLY...4014
REMOVAL AND INSTALLATION...4014
HYDRAULIC COOLER ASSEMBLY...4015
REMOVAL AND INSTALLATION...4015
RADIATOR, HYDRAULIC COOLER ASSEMBLY...4016
REMOVAL...4016
INSTALLATION...4017
ENGINE, MAIN PUMP ASSEMBLY...4018
DAMPER ASSEMBLY...4022
REMOVAL AND INSTALLATION...4022
FUEL TANK ASSEMBLY...4023
REMOVAL AND INSTALLATION...4023
CENTER SWIVEL JOINT ASSEMBLY...4024
REMOVAL AND INSTALLATION...4024
DISASSEMBLY AND ASSEMBLY...4027
FINAL DRIVE ASSEMBLY...4028
REMOVAL AND INSTALLATION...4028
DISASSEMBLY...4029
ASSEMBLY...4033
TRAVEL MOTOR ASSEMBLY...4039
DISASSEMBLY ...4039
ASSEMBLY ...4044
SPROCKET...4053
REMOVAL AND INSTALLATION...4053
SWING MOTOR ASSEMBLY...4054
REMOVAL AND INSTALLATION...4054
DISASSEMBLY...4055
ASSEMBLY...4058
SWING MACHINERY ASSEMBLY...4065
REMOVAL AND INSTALLATION...4065
DISASSEMBLY...4066
ASSEMBLY...4070
REVOLVING FRAME ASSEMBLY...4075
REMOVAL ...4075
INSTALLATION...4076
SWING CIRCLE ASSEMBLY...4077
REMOVAL AND INSTALLATION...4077
IDLER, RECOIL SPRING...4078
REMOVAL AND INSTALLATION...4078
IDER ASSEMBLY...4079
DISASSEMBLY...4079
ASSEMBLY...4080
RECOIL SPRING ASSEMBLY...4082
DISASSEMBLY...4082
ASSEMBLY...4083
TRACK ROLLER ASSEMBLY...4084
REMOVAL AND INSTALLATION...4084
DISASSEMBLY...4085
ASSEMBLY...4086
CARRIER ROLLER...4088
REMOVAL AND INSTALLATION...4088
DISASSEMBLY ...4089
ASSEMBLY...4091
TRACK SHOE ASSEMBLY...4093
REMOVAL AND INSTALLATION...4093
HYDRAULIC TANK ASSEMBLY...4094
REMOVAL ...4094
INSTALLATION...4095
MAIN PUMP ASSEMBLY...4096
REMOVAL ...4096
INSTALLATION...4098
DISASSEMBLY...4099
ASSEMBLY...4105
MAIN PUMP INPUT SHAFT OIL SEAL...4118
REMOVAL AND INSTALLATION...4118
CONTROL VALVE ASSEMBLY...4119
REMOVAL ...4119
INSTALLATION...4121
DISASSEMBLY...4122
ASSEMBLY...4128
PUMP MERGE/DIVIDER VALVE ASSEMBLY...4135
REMOVAL AND INSTALLATION...4135
PRESSURE COMPENSATION VALVE...4136
DISASSEMBLY AND ASSEMBLY...4136
SERVO VALVE ASSEMBLY FOR FRONT PUMP...4137
REMOVAL AND INSTALLATION...4137
SERVO VALVE ASSEMBLY FOR REAR PUMP...4138
REMOVAL AND INSTALLATION...4138
LS-EPC SOLENOID VALVE ASSEMBLY...4139
REMOVAL AND INSTALLATION...4139
SOLENOID VALVE ASSEMBLY...4140
REMOVAL AND INSTALLATION...4140
WORK EQUIPMENT PPC VALVE ASSEMBLY...4141
REMOVAL AND INSTALLATION...4141
DISASSEMBLY...4142
ASSEMBLY...4143
TRAVEL PPC VALVE ASSEMBLY...4144
REMOVAL AND INSTALLATION...4144
DISASSEMBLY...4146
ASSEMBLY...4146
PPC SHUTTLE VALVE ASSEMBLY...4147
REMOVAL...4147
INSTALLATION...4148
DIASSEMBLY...4149
ASSEMBLY...4150
BOOM LOCK VALVE ASSEMBLY...4151
REMOVAL AND INSTALLATION...4151
DISASSEMBLY AND ASSEMBLY...4152
BOOM CYLINDER ASSEMBLY...4153
REMOVAL...4153
INSTALLATION...4154
ARM CYLINDER ASSEMBLY...4155
REMOVAL ...4155
INSTALLATION...4156
BUCKET CYLINDER ASSEMBLY...4157
REMOVAL ...4157
INSTALLATION...4158
HYDRAULIC CYLINDER ASSEMBLY...4159
DISASSEMBLY...4159
ASSEMBLY...4162
WORK EQUIPMENT ASSEMBLY...4166
REMOVAL ...4166
INSTALLATION...4167
BUCKET ASSEMBLY...4168
REMOVAL ...4168
INSTALLATION...4169
ARM ASSEMBLY...4170
REMOVAL ...4170
INSTALLATION...4171
BUCKET, ARM ASSEMBLY...4172
REMOVAL...4172
INSTALLATION...4173
BOOM ASSEMBLY...4174
REMOVAL...4174
INSTALLATION...4175
OPERATOR'S CAB...4176
REMOVAL ...4176
INSTALLATION...4177
COUNTERWEIGHT ...4178
REMOVAL AND INSTALLATION...4178
AIR CONDITIONER COMPRESSOR ASSEMBLY...4179
REMOVAL AND INSTALLATION...4179
AIR CONDITIONER CONDENSER ASSEMBLY...4180
REMOVAL AND INSTALLATION...4180
RECEIVER TANK ASSEMBLY...4181
REMOVAL AND INSTALLATION...4181
AIR CONDITIONER UNIT ASSEMBLY...4182
REMOVAL ...4182
INSTALLATION...4183
GOVERNOR, PUMP CONTROLLER ASSEMBLY...4184
REMOVAL AND INSTALLATION...4184
MONITOR PANEL ASSEMBLY...4185
REMOVAL AND INSTALLATION...4185
CONTROL STAND CASE...4186
REMOVAL...4186
INSTALLATION...4187
40 MAINTENANCE STANDARD...4188
ENGINE MOUNT...4189
SWING MACHINERY...4190
SWING CIRCLE...4192
FINAL DRIVE...4194
TRACK FRAME AND RECOIL SPRING...4196
IDER...4197
CARRIER ROLLER...4199
TRACK ROLLER...4200
TRACK SHOE...4201
HYDRAULIC PUMP...4205
CONTROL VALVE...4206
SELF-REDUCING PRESSURE VALVE...4213
SUCTION-SAFETY VALVE...4214
SWING MOTOR...4215
TRAVEL MOTOR...4216
WORK EQUIPMENT - SWING PPC VALVE...4217
TRAVEL PPC VALVE...4218
SERVICE PPC VALVE...4219
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE...4220
LS-EPC VALVE...4221
SOLENOID VALVE...4222
CENTER SWIVEL JOINT...4223
BOOM HOLDING VALVE...4225
HYDRAULIC CYLINDER...4226
WORK EQUIPMENT...4228
DIMENSION OF WORK EQUIPMENT...4230
90 OTHERS...4234
HYDRAULIC CIRCUIT DIAGRAM...4235
ELECTRIC CIRCUIT DIAGRAM (1/3) WITH POWER WINDOW...4236
ELECTRIC CIRCUIT DIAGRAM (2/3) WITH POWER WINDOW...4237
ELECTRIC CIRCUIT DIAGRAM (3/3) WITH POWER WINDOW...4238
ELECTRIC CIRCUIT DIAGRAM (1/3) WITH POWER WINDOW...4239
ELECTRIC CIRCUIT DIAGRAM (2/3) WITH POWER WINDOW...4240
ELECTRIC CIRCUIT DIAGRAM (3/3) WITH POWER WINDOW...4241
SEBM025800 - Hydraulic Excavator PC300, 300LC-7, PC350, PC350LC-7 Shop Manual...4243
SEBM025800 - Hydraulic Excavator PC300-7, PC300LC-7, PC350-7, PC350LC-7 Shop Manual...4483
SEBM025811 - Hydraulic Excavator PC300-7, PC300LC-7, PC350-7, PC350LC-7 Shop Manual...4723
COVER...4723
CONTENTS...4724
01 GENERAL...4751
SPECIFICATION DIMENSION DRAWINGS...4752
SPECIFICATIONS...4754
PC300-7,PC300LC-7...4754
PC350-7,PC350LC-7...4756
WEIGHT TABLE...4758
PC300-7,PC300LC-7...4758
PC350-7,PC350LC-7...4760
FUEL, COOLANT, AND LUBRICANTS...4762
10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD...4763
ENGINE RELATED PARTS...4764
RADIATOR・OIL COOLER・AFTERCOOLER...4765
POWER TRAIN...4766
FINAL DRIVE...4767
SPROCKET...4769
SWING MACHINERY...4771
SWING CIRCLE...4773
TRACK FRAME・RECOIL SPRING...4774
IDLER...4776
CARRIER ROLLER...4778
TRACK ROLLER...4779
TRACK SHOE...4780
HYDRAULIC EQUIPMENT LAYOUT DRAWING...4784
HYDRAULIC TANK...4786
HYDRAULIC PUMP...4787
VARIABLE VOLUME VALVE...4808
CONTROL VALVE...4810
CLSS...4825
SELF PRESSURE REDUCING VALVE...4828
SWING MOTOR...4831
REVERSE PREVENTION VALVE...4836
CENTER SWIVEL JOINT...4838
TRAVEL MOTOR...4839
TRAVEL JUNCTION VALVE...4849
TRAVEL PPC SHUTTLE VALVE...4851
VALVE CONTROL...4855
WORK EQUIPMENT・SWING PPC VALVE...4856
TRAVEL PPC VALVE...4860
SERVICE PPC VALVE...4869
SOLENOID VALVE...4872
PPC ACCUMULATOR...4874
RETURN OIL FILTER...4875
BOOM HYDRAULIC DRIFT PREVENTION VALVE...4876
QUICK RETURN VALVE...4882
LIFT CHECK VALVE...4884
ATTACHMENT CIRCUIT SELECTOR VALVE...4885
HYDRAULIC CYLINDER...4887
WORK EQUIPMENT...4889
AIR CONDITIONER...4895
ENGINE CONTROL...4896
ELECTRONIC CONTROL SYSTEM...4902
MULTI MONITOR SYSTEM...4926
7-SEGMENT MONITOR SYSTEM...4946
SENSOR...4953
20 TESTING AND ADJUSTING...4956
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...4957
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...4958
TESTING AND ADJUSTING...4966
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...4967
INSPECTION AND ADJUSTMENT OF ENGINE RPM...4969
MEASUREMENT OF AIR BOOST PRESSURE...4971
MEASUREMENT OF EXHAUST GAS COLOR...4972
ADJUSTMENT OF VALVE CLEARANCE...4973
MEASUREMENT OF COMPRESSION PRESSURE...4975
MEASUREMENT OF BLOW-BY PRESSURE...4976
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING...4977
MEASUREMENT OF ENGINE OIL PRESSURE...4979
ADJUSTMENT OF ENGINE SPEED SENSOR...4980
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION...4980
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM...4981
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS...4982
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION...4983
INSPECTION OF WEAR ON SPROCKET...4983
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL...4984
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE...4988
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE...4989
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE...4992
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE...4996
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE...4999
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE...5000
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT...5001
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT...5002
MEASUREMENT OF OIL LEAKAGE AMOUNT...5003
AIR BLEEDING OF VARIOUS PARTS...5005
INSPECTION PROCEDURES FOR DIODE...5007
SPECIAL FUNCTION OF MULTI-MONITOR PANEL...5008
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL...5033
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM...5049
TROUBLESHOOTING...5055
POINTS TO REMEMBER WHEN TROUBLESHOOTING...5056
SEQUENCE OF EVENTS IN TROUBLESHOOTING...5057
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...5058
CHECKS BEFORE TROUBLESHOOTING...5066
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...5067
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...5071
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...5103
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED...5128
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...5136
SERVICE CODE IN ELECTRICAL SYSTEM [E101] (ABNORMAL DATA IN ERROR HISTORY)...5138
SERVICE CODE IN ELECTRICAL SYSTEM [E112] (SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)...5142
SERVICE CODE IN ELECTRICAL SYSTEM [E113] (SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)...5144
SERVICE CODE IN ELECTRICAL SYSTEM [E114] (SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM)...5146
SERVICE CODE IN ELECTRICAL SYSTEM [E115] (ABNORMAL WINDSHIELD WIPER MOTION)...5148
SERVICE CODE IN ELECTRICAL SYSTEM [E116] (ABNORMALITY IN RETRACTING WINDSHIELD WIPER)...5150
SERVICE CODE IN ELECTRICAL SYSTEM [E201] (SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)...5152
SERVICE CODE IN ELECTRICAL SYSTEM [E203] (SHORT-CIRCUITING IN SWING AND PARKING BRAKE SOLENOID-IN GOVERNOR・PUMP CONTROLLER SYSTEM)...5156
SERVICE CODE IN ELECTRICAL SYSTEM [E204] (SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)...5160
SERVICE CODE IN ELECTRICAL SYSTEM [E205] (SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)...5164
SERVICE CODE IN ELECTRICAL SYSTEM [E206] (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID)...5168
SERVICE CODE IN ELECTRICAL SYSTEM [E211] (DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)...5172
SERVICE CODE IN ELECTRICAL SYSTEM [E213] (DISCONNECTION IN SWING PARKING BRAKE SOLENOID)...5176
SERVICE CODE IN ELECTRICAL SYSTEM [E214] (DISCONNECTION OF MERGE/DIVIDE SOLENOID)...5180
SERVICE CODE IN ELECTRICAL SYSTEM [E215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID)...5184
SERVICE CODE IN ELECTRICAL SYSTEM [E216] (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)...5188
SERVICE CODE IN ELECTRICAL SYSTEM [E217] (ABNORMALITY IN INPUTTING MODEL CODE)...5192
SERVICE CODE IN ELECTRICAL SYSTEM [E218] (DISCONNECTION OF S-NET SIGNAL)...5194
SERVICE CODE IN ELECTRICAL SYSTEM [E222] (SHORT-CIRCUITING IN LS-EPC SOLENOID)...5196
SERVICE CODE IN ELECTRICAL SYSTEM [E223] (DISCONNECTION IN LS-EPC SOLENOID SYSTEM)...5197
SERVICE CODE IN ELECTRICAL SYSTEM [E224] (ABNORMALITY IN F PUMP PRESSURE SENSOR)...5198
SERVICE CODE IN ELECTRICAL SYSTEM [E225] (ABNORMALITY IN R PUMP PRESSURE SENSOR)...5200
SERVICE CODE IN ELECTRICAL SYSTEM [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE)...5202
SERVICE CODE IN ELECTRICAL SYSTEM [E227] (ABNORMALITY IN ENGINE ROTATION SENSOR IN GOVERNOR・PUMP CONTROLLER SYSTEM)...5204
SERVICE CODE IN ELECTRICAL SYSTEM [E228] (SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)...5205
SERVICE CODE IN ELECTRICAL SYSTEM [E232] (SHORT-CIRCUITING IN PC-EPC SOLENOID)...5206
SERVICE CODE IN ELECTRICAL SYSTEM [E233] (DISCONNECTION IN PC-EPC SOLENOID SYSTEM)...5208
SERVICE CODE IN ELECTRICAL SYSTEM [E238] (DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY)...5210
SERVICE CODE IN ELECTRICAL EQUIPMENT [E245] (SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)(MULTI-MONITOR ONLY)...5212
SERVICE CODE IN ELECTRICAL SYSTEM [E246] (DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)(MULTI-MONITOR ONLY)...5213
SERVICE CODE IN ELECTRICAL SYSTEM [E256] (INCORRECT NONVOLATILE MEMORY DATA)...5214
SERVICE CODE IN ELECTRICAL SYSTEM [E304] (SHORT CIRCUIT OF ENGINE STOP SOLENOID RELAY)...5215
SERVICE CODE IN ELECTRICAL SYSTEM [E306] (ABNORMALITY IN GOVERNOR POTENTIOMETER)...5218
SERVICE CODE IN ELECTRICAL SYSTEM [E308] (ABNORMALITY IN FUEL DIAL)...5220
SERVICE CODE IN ELECTRICAL SYSTEM [E314] (DISCONNECTION OF ENGINE STOP SOLENOID RELAY)...5222
SERVICE CODE IN ELECTRICAL SYSTEM [E315] (SHORT-CIRCUITING IN BATTERY RELAY)...5225
SERVICE CODE IN ELECTRICAL SYSTEM [E316] (STEP-OUT IN GOVERNOR MOTOR)...5227
SERVICE CODE IN ELECTRICAL SYSTEM [E317] (DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B)...5228
SERVICE CODE IN ELECTRICAL SYSTEM [E318] (SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PHASE B)...5230
FAILURE CODE IN MECHANICAL SYSTEM [A000N1] (OUT-OF-RATE ENGINE ROTATION AT HIGH IDLING)...5232
FAILURE CODE IN MECHANICAL SYSTEM [A000N2] (OUT-OF-RATE ENGINE ROTATION AT LOW IDLING)...5232
FAILURE CODE IN MECHANICAL SYSTEM [AA10NX] (AIR CLEANER CLOGGING)...5233
FAILURE CODE IN MECHANICAL SYSTEM [AB00KE] (ABNORMALLY LOWERED CHARGING VOLTAGE)...5234
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG] (ABNORMALLY LOWERED ENGINE OIL PRESSURE)...5237
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK] (ABNORMALLY LOWERED ENGINE OIL LEVEL)...5238
FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS] (ENGINE COOLING WATER OVERHEATING)...5239
FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK] (ABNORMALLY LOWERED RADIATOR WATER LEVEL)...5240
FAILURE CODE IN MECHANICAL SYSTEM [B@HANS] (HYDRAULIC OIL OVERHEATING)...5241
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...5242
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...5243
E-1 ENGINE DOES NOT START ...5244
E-2 ENGINE STOPS WHILE IN OPERATION...5251
E-3 ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING...5252
E-4 ENGINE DOES NOT STOP...5254
E-5 AUTO-DECELERATOR DOES NOT WORK...5257
E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK...5258
E-7 PREHEATER DOES NOT WORK...5259
E-8 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE...5261
E-9 ONE-TOUCH POWER MAX. SWITCH DOES NOT WORK...5263
E-10 NO DISPLAY IN MONITOR PANEL AT ALL...5264
E-11 PART OF DISPLAY ON MONITOR PANEL IS MISSING...5266
E-12 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL...5266
E-13 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING...5267
E-14 ENGINE COOLING WATER TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY...5268
E-15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY...5269
E-16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY...5270
E-17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY...5271
E-18 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS...5272
E-19 WINDSHIELD WIPER DOES NOT WORK...5273
E-20 ALARMING BUZZER CANNOT BE CANCELLED...5275
E-21 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5276
E-22 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5277
E-23 "ARM DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5278
E-24 "ARM DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5279
E-25 "BUCKET DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5280
E-26 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5281
E-27 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5282
E-28 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5284
E-29 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5286
E-30 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...5288
E-31 AIR CONDITIONER DOES NOT WORK...5290
E-32 TRAVEL ALARM DOES NOT SOUND...5303
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...5305
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS...5306
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...5308
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW...5309
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS...5310
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE...5311
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...5311
H-5 AUTO-DECELERATOR DOES NOT WORK...5312
H-6 FINE CONTROL MODE DOES NOT FUNCTION...5312
H-7 BOOM MOVES SLOWLY OR LACKS POWER...5313
H-8 ARM MOVES SLOWLY OR LACKS POWER...5314
H-9 BUCKET MOVES SLOWLY OR LACKS POWER...5315
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION...5315
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT...5316
H-12 WORK EQUIPMENT HAS BIG TIME LAG...5317
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT...5317
H-14 ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE...5317
H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY...5318
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY...5318
H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY...5318
H-18 MACHINE SWERVES IN TRAVEL...5319
H-19 MACHINE TRAVELS SLOWLY...5320
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER...5321
H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST...5322
H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)...5322
H-23 MACHINE DOES NOT SWING...5323
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW...5324
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING...5325
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING...5326
H-27 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING...5326
H-28 SWING NATURAL DRIFT IS TOO BIG...5327
TROUBLESHOOTING OF ENGINE (S-MODE)...5328
METHOD OF USING TROUBLESHOOTING CHARTS...5329
S-1 STARTING PERFORMACE IS POOR (STARTING ALWAYS TAKES TIME)...5333
S-2 ENGINE DOES NOT START ...5335
S-3 ENGINE DOES NOT PICK UP SMOTHLY (FPLLOW-UP IS POOR)...5338
S-4 ENGINE STOPS DURING OPERATIONS...5339
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...5340
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...5341
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...5342
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...5343
S-9 OIL BECOMES CONTAMINATED QUICKLY...5344
S-10 FUEL CINSUMPTION IS EXCESSIVE...5345
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...5346
S-12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE)...5347
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...5348
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...5349
S-15 ABNORMAL NOISE IS MADE...5350
S-16 VIBRATION IS EXCESSIVE...5351
30 DISASSEMBLY AND ASSEMBLY...5352
HOW TO READ THIS MANUAL...5354
REMOVAL AND INSTALLATION OF ASSEMBLIES...5354
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...5355
PRECAUTIONS WHEN PERFORMING OPERATION...5356
SPECIAL TOOL LIST...5358
SKETCHES OF SPECIAL TOOLS...5362
STARTING MOTOR ASSEMBLY...5364
REMOVAL...5364
INSTALLATION...5364
FUEL INJECTION PUMP ASSEMBLY...5365
SPECIAL TOOLS...5365
REMOVAL...5365
INSTALLATION...5367
ENGINE FRONT SEAL...5369
REMOVAL...5369
INSTALLATION...5370
ENGINE REAR SEAL...5371
SPECIAL TOOLS ...5371
REMOVAL...5371
INSTALLATION...5372
CYLINDER HEAD ASSEMBLY...5377
SPECIAL TOOLS...5377
REMOVAL...5377
INSTALLATION...5380
RADIATOR ASSEMBLY...5383
REMOVAL...5383
INSTALLATION...5384
HYDRAULIC OIL COOLER ASSEMBLY...5385
REMOVAL...5385
INSTALLATION...5386
ENGINE AND HYDRAULIC PUMP ASSEMBLIES...5387
SPECIAL TOOLS...5387
REMOVAL...5387
INSTALLATION...5390
FINAL DRIVE ASSEMBLY...5391
REMOVAL...5391
INSTALLATION...5391
DISASSEMBLY AND ASSEMBLY...5392
SPECIAL TOOLS...5392
DISASSEMBLY...5392
ASSEMBLY...5395
SWING MOTOR,SWING MACHINERY ASSEMBLY...5401
REMOVAL...5401
INSTALLATION...5401
DISASSEMBLY AND ASSEMBLY...5402
SPECIAL TOOLS...5402
DISASSEMBLY...5402
ASSEMBLY...5404
SWING MOTOR,SWING MACHINERY ASSEMBLY...5409
SPECIAL TOOLS ...5409
DISASSEMBLY...5409
ASSEMBLY...5411
CARRIER ROLLER ASSEMBLY...5417
SPECIAL TOOLS...5417
ASSEMBLY...5417
TRACK ROLLER ASSEMBLY...5418
SPECIAL TOOLS...5418
ASSEMBLY...5418
IDLER ASSEMBLY...5419
SPECIAL TOOLS...5419
DISASSEMBLY...5419
ASSEMBLY...5420
RECOIL SPRING ASSEMBLY...5422
SPECIAL TOOLS...5422
DISASSEMBLY...5422
ASSEMBLY...5423
SPROCKET...5424
REMOVAL...5424
INSTALLATION...5424
TRACK SHOE ASSEMBLY...5425
SPECIAL TOOLS...5425
EXPANSION OF TRACK SHOE...5425
ASSEMBLY...5426
SWING CIRCLE ASSEMBLY...5427
REMOVAL...5427
INSTALLATION...5427
REVOLVING FRAME ASSEMBLY...5428
REMOVAL...5428
INSTALLATION...5430
CENTER SWIVEL JOINT ASSEMBLY...5431
REMOVAL...5431
INSTALLATION...5432
DISASSEMBLY AND ASSEMBLY...5433
SPECIAL TOOLS...5433
DISASSEMBLY...5433
ASSEMBLY...5433
HYDRAULIC TANK ASSEMBLY...5434
REMOVAL...5434
INSTALLATION...5435
CONTROL VALVE ASSEMBLY...5436
REMOVAL...5436
INSTALLATION...5438
DISASSEMBLY AND ASSEMBLY...5439
SPECIAL TOOLS...5439
ASSEMBLY...5440
HYDRAULIC PUMP ASSEMBLY...5443
SPECIAL TOOLS...5443
REMOVAL...5443
INSTALLATION...5445
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT...5446
REMOVAL...5446
INSTALLATION...5446
WORK EQUIPMENT PPC VALVE ASSEMBLY...5447
ASSEMBLY...5447
TRAVEL PPC VALVE ASSEMBLY...5449
ASSEMBLY...5449
HYDRAULIC CYLINDER ASSEMBLY...5450
SPECIAL TOOLS...5450
DISASSEMBLY...5450
ASSEMBLY...5452
WORK EQUIPMENT ASSEMBLY...5456
SPECIAL TOOLS...5456
REMOVAL...5456
INSTALLATION...5457
AIR CONDITIONER UNIT ASSEMBLY...5459
SPECIAL TOOLS...5459
REMOVAL...5459
INSTALLATION...5461
COUNTERWEIGHT ASSEMBLY...5464
REMOVAL...5464
INSTALLATION...5464
OPERATOR'S CAB ASSEMBLY...5465
REMOVAL...5465
INSTALLATION...5466
OPERATOR'S CAB GLASS (STUCK GLASS)...5470
SPECIAL TOOLS ...5471
REMOVAL...5471
INSTALLATION...5472
FRONT WINDOW ASSEMBLY...5480
REMOVAL...5480
INSTALLATION...5482
MONITOR ASSEMBLY...5486
REMOVAL...5486
INSTALLATION...5486
GOVERNOR PUMP CONTROLLER ASSEMBLY...5487
REMOVAL...5487
INSTALLATION...5487
90 OTHERS...5488
HYDRAULIC CIRCUIT DIAGRAM...5489
PC300-7, PC300LC-7: SERIAL NO.40001-45000 PC300-7, PC350LC-7: SERIAL NO.20001-25000 ...5490
ELECTRICAL CIRCUIT DIAGRAM (1/4)...5490
ELECTRICAL CIRCUIT DIAGRAM (2/4)...5491
ELECTRICAL CIRCUIT DIAGRAM (3/4)...5492
ELECTRICAL CIRCUIT DIAGRAM (4/4)...5493
PC300-7, PC300LC-7: SERIAL NO.45001 AND UP PC300-7, PC350LC-7: SERIAL NO.25001 AND UP...5494
ELECTRICAL CIRCUIT DIAGRAM (1/4)...5494
ELECTRICAL CIRCUIT DIAGRAM (2/4)...5495
ELECTRICAL CIRCUIT DIAGRAM (3/4)...5496
ELECTRICAL CIRCUIT DIAGRAM (4/4)...5497
SEN01983-01 - Hydraulic Excavator PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual...5498
COVER...5498
00 INDEX AND FOREWORD...0
INDEX...5500
COMPOSITION OF SHOP MANUAL...5501
TABLE OF CONTENTS...5503
FOREWORD AND GENERAL INFORMATION...5510
SAFETY NOTICE...5511
HOW TO READ THE SHOP MANUAL...5516
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...5518
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT...5520
HANDLING OF CONNECTORS NEWLY USED FOR ENGINES...5529
HOW TO READ ELECTRIC WIRE CODE...5532
PRECAUTIONS WHEN CARRYING OUT OPERATION...5535
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER...5538
STANDARD TIGHTENING TORQUE TABLE...5541
CONVERSION TABLE...5545
01 SPECIFICATION...0
SPECIFICATION AND TECHNICAL DATA...5552
SPECIFICATION DIMENSION DRAWINGS...5553
SPECIFICATIONS...5555
WEIGHT TABLE...5561
TABLE OF FUEL, COOLANT AND LUBRICANTS...5563
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...0
ENGINE AND COOLING SYSTEM...5566
ENGINE RELATED PARTS...5567
RADIATOR, OIL COOLER AND AFTERCOOLER...5568
POWER TRAIN...5570
POWER TRAIN...5571
SWING CIRCLE...5572
SWING MACHINERY...5573
FINAL DRIVE...5575
SPROCKET...5577
UNDERCARRIAGE AND FRAME...5580
TRACK FRAME AND RECOIL SPRING...5581
IDLER...5583
CARRIER ROLLER...5585
TRACK ROLLER...5586
TRACK SHOE...5587
HYDRAULIC SYSTEM, PART 1...5592
HYDRAULIC EQUIPMENT LAYOUT DRAWING...5593
HYDRAULIC TANK AND FILTER...5595
HYDRAULIC PUMP...5597
HYDRAULIC SYSTEM, PART 2...5622
CONTROL VALVE...5623
CLSS...5635
FUNCTIONS AND OPERATION BY VALVE...5639
MERGE-DIVIDER VALVE...5654
ATTACHMENT CIRCUIT SELECTOR VALVE...5679
HYDRAULIC DRIFT PREVENTION VALVE...5681
HYDRAULIC SYSTEM, PART 3...5688
VALVE CONTROL...5689
PPC VALVE...5691
SOLENOID VALVE...5713
PPC ACCUMULATOR...5715
RETURN OIL FILTER...5716
CENTER SWIVEL JOINT...5717
TRAVEL MOTOR...5718
SWING MOTOR...5730
HYDRAULIC CYLINDER...5739
WORK EQUIPMENT...5742
WORK EQUIPMENT...5743
DIMENSIONS OF COMPONENTS...5745
CAB AND ITS ATTACHMENTS...5750
AIR CONDITIONER PIPING...5751
ELECTRICAL SYSTEM...5754
ENGINE CONTROL...5755
ELECTRONIC CONTROL SYSTEM...5764
MONITOR SYSTEM...5789
SENSOR...5816
KOMTRAX TERMINAL SYSTEM...5819
20 STANDARD VALUE TABLE...0
STANDARD SERVICE VALUE TABLE ...5822
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...5823
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...5824
30 TESTING AND ADJUSTING...0
TESTING AND ADJUSTING, PART 1 ...5836
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...5838
MEASURING ENGINE SPEED...5842
MEASURING AIR BOOST PRESSURE...5843
MEASURING EXHAUST GAS COLOR ...5844
ADJUSTING VALVE CLEARANCE ...5846
MEASURING COMPRESSION PRESSURE...5848
MEASURING BLOW-BY PRESSURE...5852
MEASURING ENGINE OIL PRESSURE...5853
MEASURING FUEL PRESSURE...5854
HANDLING DURING CYLINDER CUT-OUT OPERATION ...5858
HANDLING DURING NO INJECTION CRANKING OPERATION ...5858
MEASURING FUEL RETURN RATE AND LEAKAGE...5859
BLEEDING AIR FROM FUEL CIRCUIT ...5861
CHECKING FUEL CIRCUIT FOR LEAKAGE...5862
TESTING AND ADJUSTING AIR COMPRESSOR BELT TENSION ...5863
MEASURING CLEARANCE IN SWING CIRCLE BEARINGS...5864
TESTING AND ADJUSTING TRACK SHOE TENSION...5865
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT...5866
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE...5870
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE...5871
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE ...5874
MEASURING SOLENOID VALVE OUTPUT PRESSURE...5879
MEASURING PPC VALVE OUTPUT PRESSURE ...5883
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES...5884
INSPECTING LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT ...5885
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ...5887
MEASURING OIL LEAKAGE AMOUNT ...5887
BLEEDING AIR FROM VARIOUS PARTS ...5890
DIODE INSPECTION PROCEDURES...5892
TESTING AND ADJUSTING, PART 2 ...5894
SPECIAL FUNCTIONS OF MACHINE MONITOR...5895
TESTING AND ADJUSTING, PART 3 ...5952
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...5953
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM...5954
PROCEDURE FOR TESTING DIODES...5958
PM CLINIC SERVICE...5959
40 TROUBLESHOOTING...0
FAILURE CODE TABLE AND FUSE LOCATIONS...5966
FAILURE CODES TABLE...5967
FUSE LOCATIONS ...5970
GENERAL INFORMATION ON TROUBLESHOOTING ...5976
POINTS TO REMEMBER WHEN TROUBLESHOOTING...5977
SEQUENCE OF EVENTS IN TROUBLESHOOTING ...5978
CHECKS BEFORE TROUBLESHOOTING...5979
CLASSIFICATION AND TROUBLESHOOTING STEPS...5980
INFORMATION IN TROUBLESHOOTING TABLE...5981
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...5986
T-ADAPTER BOX AND T-ADAPTER TABLE...6020
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1 ...6024
FAILURE CODE [A000N1] ENG. HI OUT OF STD...6026
FAILURE CODE [AA10NX] AIR CLEANER CLOGGING...6027
FAILURE CODE [AB00KE] CHARGE VOLTAGE LOW...6029
FAILURE CODE [B@BAZG] ENG OIL PRESS. LOW...6031
FAILURE CODE [B@BAZK] ENG OIL LEVEL LOW ...6033
FAILURE CODE [B@BCNS] ENG. WATER OVERHEAT...6035
FAILURE CODE [B@BCZK] ENG WATER LEVEL LOW...6037
FAILURE CODE [B@HANS] HYDR OIL OVERHEAT ...6039
FAILURE CODE [CA111] EMC CRITICAL INTERNAL FAILURE ...6040
FAILURE CODE [CA115] ENG NE AND BKUP SPEED SENS ERROR...6040
FAILURE CODE [CA122] CHG AIR PRESS SENSOR HIGH ERROR...6041
FAILURE CODE [CA123] CHG AIR PRESS SENSOR LOW ERROR...6043
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR...6045
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR ...6047
FAILURE CODE [CA144] COOLANT TEMP SENS HIGH ERROR...6049
FAILURE CODE [CA145] COOLANT TEMP SENS LOW ERROR...6051
FAILURE CODE [CA153] CHG AIR TEMP SENSOR HIGH ERROR...6053
FAILURE CODE [CA154] CHG AIR TEMP SENSOR LOW ERROR...6055
FAILURE CODE [CA187] SENS SUPPLY 2 VOLT LOW ERROR...6057
FAILURE CODE [CA221] AMBIENT PRESS SENS HIGH ERROR...6059
FAILURE CODE [CA222] AMBIENT PRESS SENS LOW ERROR...6061
FAILURE CODE [CA227] SENS SUPPLY 2 VOLT HIGH ERROR ...6063
FAILURE CODE [CA234] ENG OVERSPEED ...6064
FAILURE CODE [CA238] NE SPEED SENS SUPPLY VOLT ERROR...6065
FAILURE CODE [CA271] IMV/PCV1 SHORT ERROR...6066
FAILURE CODE [CA272] IMV/PCV1 OPEN ERROR ...6067
FAILURE CODE [CA322] INJ #1 OPEN/SHORT ERROR...6069
FAILURE CODE [CA323] INJ #5 OPEN/SHORT ERROR...6071
FAILURE CODE [CA324] INJ #3 OPEN/SHORT ERROR...6073
FAILURE CODE [CA325] INJ #6 OPEN/SHORT ERROR ...6075
FAILURE CODE [CA331] INJ #2 OPEN/SHORT ERROR ...6077
FAILURE CODE [CA332] INJ #4 OPEN/SHORT ERROR...6079
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2 ...6082
FAILURE CODE [CA342] CALIBRATION CODE INCOMPATIBILITY...6084
FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR...6085
FAILURE CODE [CA352] SENS SUPPLY 1 VOLT LOW ERROR...6087
FAILURE CODE [CA386] SENS SUPPLY 1 VOLT HIGH ERROR...6089
FAILURE CODE [CA428] WATER IN FUEL SENSOR HIGH ERROR ...6091
FAILURE CODE [CA429] WATER IN FUEL SENSOR LOW ERROR...6093
FAILURE CODE [CA441] BATTERY VOLTAGE LOW ERROR...6095
FAILURE CODE [CA442] BATTERY VOLTAGE HIGH ERROR...6097
FAILURE CODE [CA449] RAIL PRESS VERY HIGH ERROR...6099
FAILURE CODE [CA451] RAIL PRESS SENSOR HIGH ERROR...6103
FAILURE CODE [CA452] RAIL PRESS SENSOR LOW ERROR...6105
FAILURE CODE [CA553] RAIL PRESS HIGH ERROR...6107
FAILURE CODE [CA559] RAIL PRESS LOW ERROR ...6108
FAILURE CODE [CA689] ENG NE SPEED SENSOR ERROR...6110
FAILURE CODE [CA731] ENG BKUP SPEED SENS PHASE ERROR ...6112
FAILURE CODE [CA757] ALL PERSISTENT DATA LOST ERROR...6113
FAILURE CODE [CA778] ENG BKUP SPEED SENSOR ERROR ...6115
FAILURE CODE [CA1633] KOMNET DATALINK TIMEOUT ERROR...6117
FAILURE CODE [CA2185] THROT SENS SUP VOLT HIGH ERROR ...6119
FAILURE CODE [CA2186] THROT SENS SUP VOLT LOW ERROR...6120
FAILURE CODE [CA2249] RAIL PRESS VERY LOW ERROR ...6121
FAILURE CODE [CA2265] ELECTRIC LIFT PUMP HIGH ERROR ...6123
FAILURE CODE [CA2266] ELECTRIC LIFT PUMP LOW ERROR...6125
FAILURE CODE [CA2555] GRID HTR RELAY VOLT HIGH ERROR ...6127
FAILURE CODE [CA2556] GRID HTR RELAY VOLT LOW ERROR ...6129
FAILURE CODE [D110KB] BATTERY RELAY DRIVE S/C...6131
FAILURE CODE [DA25KP] 5V SENSOR 1 POWER ABNORMALITY ...6133
FAILURE CODE [DA2RMC] PUMP COMM. ABNORMALITY...6137
FAILURE CODE [DA2SKQ] MODEL SELECTION ABNORMALITY...6139
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3 ...6142
FAILURE CODE [DAFRMC] CAN DISCON (MONITOR DETECTED) ...6145
FAILURE CODE [DHPAMA] F PUMP PRESS SENSOR ABNORMALITY ...6147
FAILURE CODE [DHPBMA] R PUMP PRESS SENSOR ABNORMALITY...6149
FAILURE CODE [DHS3MA] ARM CURL PPC SEN. ABNORMALITY...6151
FAILURE CODE [DHS4MA] BUCKET CURL PPC PRESS SENSOR ABNORMALITY ...6153
FAILURE CODE [DW43KA] TRAVEL SPEED SOL. DISC...6155
FAILURE CODE [DW43KB] TRAVEL SPEED SOL. S/C...6157
FAILURE CODE [DW45KA] SWING BRAKE SOL. DISC. ...6159
FAILURE CODE [DW45KB] SWING BRAKE SOL. S/C...6163
FAILURE CODE [DW91KA] TRAVEL JUNCTION SOL. DISC...6165
FAILURE CODE [DW91KB] TRAVEL JUNCTION SOL. S/C...6167
FAILURE CODE [DWJ0KA] MERGE-DIVIDER SOL. DISC. ...6169
FAILURE CODE [DWJ0KB] MERGE-DIVIDER SOL. S/C...6171
FAILURE CODE [DWK0KA] 2-STAGE RELIEF SOL. DISC...6173
FAILURE CODE [DWK0KB] 2-STAGE RELIEF SOL. S/C...6175
FAILURE CODE [DXA0KA] PC-EPC SOL. DISC...6177
FAILURE CODE [DXA0KB] PC-EPC SOL. S/C...6179
FAILURE CODE [DXE0KA] LS-EPC SOL. DISC...6181
FAILURE CODE [DXE0KB] LS-EPC SOL. S/C...6183
FAILURE CODE [DXE4KA] SERVICE CURRENT EPC DISC...6185
FAILURE CODE [DXE4KB] SERVICE CURRENT EPC S/C...6186
FAILURE CODE [DY20KA] WIPER WORKING ABNORMALITY ...6187
FAILURE CODE [DY20MA] WIPER PARKING ABNORMALITY ...6189
FAILURE CODE [DY2CKB] WASHER DRIVE SHORT ...6191
FAILURE CODE [DY2DKB] WIPER DRIVE (FOR) SHORT...6193
FAILURE CODE [DY2EKB] WIPER DRIVE (REV) SHORT ...6195
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ...6198
BEFORE CARRYING OUT TROUBLESHOOTING OF ELECTRICAL SYSTEM...6201
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...6203
E-1 ENGINE DOES NOT START...6204
E-2 AUTO-DECELERATOR DOES NOT OPERATE ...6207
E-3 AUTOMATIC WARMING-UP SYSTEM DOES NOT OPERATE ...6209
E-4 PREHEATER DOES NOT OPERATE ...6211
E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE...6213
E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE...6215
E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL ...6217
E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS...6219
E-9 CONTENTS OF DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE...6219
E-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUNNING...6220
E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY ...6221
E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...6223
E-13 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY...6224
E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY...6225
E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTHING...6227
E-16 WINDSHIELD WIPER AND WINDOW WASHER DO NOT OPERATE ...6229
E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY ...6233
E-18 MONITORING FUNCTION FAILS TO DISPLAY “ BOOM RAISE ” NORMALLY ...6235
E-19 MONITORING FUNCTION FAILS TO DISPLAY “ BOOM LOWER ” NORMALLY ...6237
E-20 MONITORING FUNCTION FAILS TO DISPLAY “ ARM IN ” NORMALLY ...6239
E-21 MONITORING FUNCTION FAILS TO DISPLAY “ ARM OUT ” NORMALLY ...6241
E-22 MONITORING FUNCTION FAILS TO DISPLAY “ BUCKET CURL ” NORMALLY ...6243
E-23 MONITORING FUNCTION FAILS TO DISPLAY “ BUCKET DUMP ” NORMALLY ...6245
E-24 MONITORING FUNCTION FAILS TO DISPLAY “ SWING ” NORMALLY...6247
E-25 MONITORING FUNCTION FAILS TO DISPLAY “ TRAVEL ” NORMALLY ...6249
E-26 MONITORING FUNCTION FAILS TO DISPLAY “ TRAVEL DIFFERENTIAL PRESSURE ” NORMALLY ...6251
E-27 MONITORING FUNCTION FAILS TO DISPLAY “ SERVICE ” NORMALLY...6253
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ...6255
E-29 AIR CONDITIONER DOES NOT OPERATE...6257
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING ...6259
E-31 HORN DOES NOT SOUND...6261
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ...6264
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM ...6267
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...6269
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW...6271
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS ...6273
H-3 NO WORK EQUIPMENT, SWING OR TRAVEL MOVE...6274
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...6274
H-5 AUTO-DECELERATOR DOES NOT WORK...6275
H-6 FINE CONTROL MODE DOES NOT FUNCTION OR RESPONDS SLOW ...6275
H-7 BOOM MOVES SLOWLY OR LACKS POWER ...6276
H-8 ARM MOVES SLOWLY OR LACKS POWER...6277
H-9 BUCKET MOVES SLOWLY OR LACKS POWER...6278
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION ...6278
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT...6279
H-12 WORK EQUIPMENT HAS BIG TIME LAG...6281
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT...6281
H-14 POWER MAX. SWITCH DOES NOT OPERATE...6282
H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY ...6282
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY...6283
H-17 IN SWING + TRAVEL OPERATION, TRAVEL SPEED DROPS SHARPLY...6283
H-18 MACHINE SWERVES IN TRAVEL...6284
H-19 MACHINE TRAVELS SLOWLY ...6285
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER...6286
H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST...6287
H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)...6288
H-23 MACHINE DOES NOT SWING...6289
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW ...6291
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING...6293
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING ...6294
H-27 LARGE SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING...6294
H-28 SWING HYDRAULIC DRIFT IS TOO BIG ...6295
TROUBLESHOOTING OF ENGINE (S-MODE) ...6298
METHOD OF USING TROUBLESHOOTING CHART...6300
S-1 STARTING PERFORMANCE IS POOR...6303
S-2 ENGINE DOES NOT START...6304
S-3 ENGINE DOES NOT PICK UP SMOOTHLY ...6307
S-4 ENGINE STOPS DURING OPERATIONS ...6308
S-5 ENGINE DOES NOT ROTATE SMOOTHLY...6309
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) ...6310
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...6311
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) ...6312
S-9 OIL BECOMES CONTAMINATED QUICKLY...6313
S-10 FUEL CONSUMPTION IS EXCESSIVE...6314
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ...6315
S-12 OIL PRESSURE DROPS...6316
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)...6317
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) ...6318
S-15 ABNORMAL NOISE IS MADE...6319
S-16 VIBRATION IS EXCESSIVE...6320
90 DIAGRAMS AND DRAWINGS...0
HYDRAULIC DIAGRAMS AND DRAWINGS...6322
HYDRAULIC CIRCUIT DIAGRAM...6324
ELECTRICAL DIAGRAMS AND DRAWINGS...6327
ELECTRICAL CIRCUIT DIAGRAM...6329
CONNECTOR ARRANGEMENT DIAGRAM...6330
SEN01983-03 - Hydraulic Excavator GALEO PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual...6337
COVER...6337
00 INDEX AND FOREWORD...0
INDEX...6339
COMPOSITION OF SHOP MANUAL...6340
TABLE OF CONTENTS...6342
FOREWORD AND GENERAL INFORMATION...6351
SAFETY NOTICE...6352
HOW TO READ THE SHOP MANUAL...6357
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...6359
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT...6361
HANDLING OF CONNECTORS NEWLY USED FOR ENGINES...6370
HOW TO READ ELECTRIC WIRE CODE...6373
PRECAUTIONS WHEN CARRYING OUT OPERATION...6376
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER...6379
STANDARD TIGHTENING TORQUE TABLE...6382
CONVERSION TABLE...6386
01 SPECIFICATION...0
SPECIFICATION AND TECHNICAL DATA...6393
SPECIFICATION DIMENSION DRAWINGS...6394
SPECIFICATIONS...6396
WEIGHT TABLE...6402
TABLE OF FUEL, COOLANT AND LUBRICANTS...6404
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...0
ENGINE AND COOLING SYSTEM...6407
ENGINE RELATED PARTS...6408
RADIATOR, OIL COOLER AND AFTERCOOLER...6409
POWER TRAIN...6411
POWER TRAIN...6412
SWING CIRCLE...6413
SWING MACHINERY...6414
FINAL DRIVE...6416
SPROCKET...6418
UNDERCARRIAGE AND FRAME...6421
TRACK FRAME AND RECOIL SPRING...6422
IDLER...6424
CARRIER ROLLER...6426
TRACK ROLLER...6427
TRACK SHOE...6428
HYDRAULIC SYSTEM, PART 1...6433
HYDRAULIC EQUIPMENT LAYOUT DRAWING...6434
HYDRAULIC TANK AND FILTER...6436
HYDRAULIC PUMP...6438
HYDRAULIC SYSTEM, PART 2...6463
CONTROL VALVE...6464
CLSS...6476
FUNCTIONS AND OPERATION BY VALVE...6480
MERGE-DIVIDER VALVE...6495
ATTACHMENT CIRCUIT SELECTOR VALVE...6520
HYDRAULIC DRIFT PREVENTION VALVE...6522
HYDRAULIC SYSTEM, PART 3...6529
VALVE CONTROL...6530
PPC VALVE...6532
SOLENOID VALVE...6554
PPC ACCUMULATOR...6556
RETURN OIL FILTER...6557
CENTER SWIVEL JOINT...6558
TRAVEL MOTOR...6559
SWING MOTOR...6571
HYDRAULIC CYLINDER...6580
WORK EQUIPMENT...6583
WORK EQUIPMENT...6584
DIMENSIONS OF COMPONENTS...6586
CAB AND ITS ATTACHMENTS...6591
AIR CONDITIONER PIPING...6592
ELECTRICAL SYSTEM...6595
ENGINE CONTROL...6596
ELECTRONIC CONTROL SYSTEM...6605
MONITOR SYSTEM...6630
SENSOR...6657
KOMTRAX TERMINAL SYSTEM...6660
20 STANDARD VALUE TABLE...0
STANDARD SERVICE VALUE TABLE ...6663
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...6664
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...6665
30 TESTING AND ADJUSTING...0
TESTING AND ADJUSTING, PART 1 ...6677
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...6679
MEASURING ENGINE SPEED...6683
MEASURING AIR BOOST PRESSURE...6684
MEASURING EXHAUST GAS COLOR ...6685
ADJUSTING VALVE CLEARANCE ...6687
MEASURING COMPRESSION PRESSURE...6689
MEASURING BLOW-BY PRESSURE...6693
MEASURING ENGINE OIL PRESSURE...6694
MEASURING FUEL PRESSURE...6695
HANDLING DURING CYLINDER CUT-OUT OPERATION ...6699
HANDLING DURING NO INJECTION CRANKING OPERATION ...6699
MEASURING FUEL RETURN RATE AND LEAKAGE...6700
BLEEDING AIR FROM FUEL CIRCUIT ...6702
CHECKING FUEL CIRCUIT FOR LEAKAGE...6703
TESTING AND ADJUSTING AIR COMPRESSOR BELT TENSION ...6704
MEASURING CLEARANCE IN SWING CIRCLE BEARINGS...6705
TESTING AND ADJUSTING TRACK SHOE TENSION...6706
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT...6707
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE...6711
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE...6712
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE ...6715
MEASURING SOLENOID VALVE OUTPUT PRESSURE...6720
MEASURING PPC VALVE OUTPUT PRESSURE ...6724
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES...6725
INSPECTING LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT ...6726
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ...6728
MEASURING OIL LEAKAGE AMOUNT ...6728
BLEEDING AIR FROM VARIOUS PARTS ...6731
DIODE INSPECTION PROCEDURES...6733
TESTING AND ADJUSTING, PART 2 ...6735
SPECIAL FUNCTIONS OF MACHINE MONITOR...6736
TESTING AND ADJUSTING, PART 3 ...6793
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...6794
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM...6795
PROCEDURE FOR TESTING DIODES...6799
PM CLINIC SERVICE...6800
40 TROUBLESHOOTING...0
FAILURE CODE TABLE AND FUSE LOCATIONS...6807
FAILURE CODES TABLE...6808
FUSE LOCATIONS ...6811
GENERAL INFORMATION ON TROUBLESHOOTING ...6817
POINTS TO REMEMBER WHEN TROUBLESHOOTING...6818
SEQUENCE OF EVENTS IN TROUBLESHOOTING ...6819
CHECKS BEFORE TROUBLESHOOTING...6820
CLASSIFICATION AND TROUBLESHOOTING STEPS...6821
INFORMATION IN TROUBLESHOOTING TABLE...6822
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...6827
T-ADAPTER BOX AND T-ADAPTER TABLE...6861
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1 ...6865
FAILURE CODE [A000N1] ENG. HI OUT OF STD...6867
FAILURE CODE [AA10NX] AIR CLEANER CLOGGING...6868
FAILURE CODE [AB00KE] CHARGE VOLTAGE LOW...6870
FAILURE CODE [B@BAZG] ENG OIL PRESS. LOW...6872
FAILURE CODE [B@BAZK] ENG OIL LEVEL LOW ...6874
FAILURE CODE [B@BCNS] ENG. WATER OVERHEAT...6876
FAILURE CODE [B@BCZK] ENG WATER LEVEL LOW...6878
FAILURE CODE [B@HANS] HYDR OIL OVERHEAT ...6880
FAILURE CODE [CA111] EMC CRITICAL INTERNAL FAILURE ...6881
FAILURE CODE [CA115] ENG NE AND BKUP SPEED SENS ERROR...6881
FAILURE CODE [CA122] CHG AIR PRESS SENSOR HIGH ERROR...6882
FAILURE CODE [CA123] CHG AIR PRESS SENSOR LOW ERROR...6884
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR...6886
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR ...6888
FAILURE CODE [CA144] COOLANT TEMP SENS HIGH ERROR...6890
FAILURE CODE [CA145] COOLANT TEMP SENS LOW ERROR...6892
FAILURE CODE [CA153] CHG AIR TEMP SENSOR HIGH ERROR...6894
FAILURE CODE [CA154] CHG AIR TEMP SENSOR LOW ERROR...6896
FAILURE CODE [CA187] SENS SUPPLY 2 VOLT LOW ERROR...6898
FAILURE CODE [CA221] AMBIENT PRESS SENS HIGH ERROR...6900
FAILURE CODE [CA222] AMBIENT PRESS SENS LOW ERROR...6902
FAILURE CODE [CA227] SENS SUPPLY 2 VOLT HIGH ERROR ...6904
FAILURE CODE [CA234] ENG OVERSPEED ...6905
FAILURE CODE [CA238] NE SPEED SENS SUPPLY VOLT ERROR...6906
FAILURE CODE [CA271] IMV/PCV1 SHORT ERROR...6907
FAILURE CODE [CA272] IMV/PCV1 OPEN ERROR ...6908
FAILURE CODE [CA322] INJ #1 OPEN/SHORT ERROR...6910
FAILURE CODE [CA323] INJ #5 OPEN/SHORT ERROR...6912
FAILURE CODE [CA324] INJ #3 OPEN/SHORT ERROR...6914
FAILURE CODE [CA325] INJ #6 OPEN/SHORT ERROR ...6916
FAILURE CODE [CA331] INJ #2 OPEN/SHORT ERROR ...6918
FAILURE CODE [CA332] INJ #4 OPEN/SHORT ERROR...6920
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2 ...6923
FAILURE CODE [CA342] CALIBRATION CODE INCOMPATIBILITY...6925
FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR...6926
FAILURE CODE [CA352] SENS SUPPLY 1 VOLT LOW ERROR...6928
FAILURE CODE [CA386] SENS SUPPLY 1 VOLT HIGH ERROR...6930
FAILURE CODE [CA428] WATER IN FUEL SENSOR HIGH ERROR ...6932
FAILURE CODE [CA429] WATER IN FUEL SENSOR LOW ERROR...6934
FAILURE CODE [CA441] BATTERY VOLTAGE LOW ERROR...6936
FAILURE CODE [CA442] BATTERY VOLTAGE HIGH ERROR...6938
FAILURE CODE [CA449] RAIL PRESS VERY HIGH ERROR...6940
FAILURE CODE [CA451] RAIL PRESS SENSOR HIGH ERROR...6944
FAILURE CODE [CA452] RAIL PRESS SENSOR LOW ERROR...6946
FAILURE CODE [CA553] RAIL PRESS HIGH ERROR...6948
FAILURE CODE [CA559] RAIL PRESS LOW ERROR ...6949
FAILURE CODE [CA689] ENG NE SPEED SENSOR ERROR...6951
FAILURE CODE [CA731] ENG BKUP SPEED SENS PHASE ERROR ...6953
FAILURE CODE [CA757] ALL PERSISTENT DATA LOST ERROR...6954
FAILURE CODE [CA778] ENG BKUP SPEED SENSOR ERROR ...6956
FAILURE CODE [CA1633] KOMNET DATALINK TIMEOUT ERROR...6958
FAILURE CODE [CA2185] THROT SENS SUP VOLT HIGH ERROR ...6960
FAILURE CODE [CA2186] THROT SENS SUP VOLT LOW ERROR...6961
FAILURE CODE [CA2249] RAIL PRESS VERY LOW ERROR ...6962
FAILURE CODE [CA2265] ELECTRIC LIFT PUMP HIGH ERROR ...6964
FAILURE CODE [CA2266] ELECTRIC LIFT PUMP LOW ERROR...6966
FAILURE CODE [CA2555] GRID HTR RELAY VOLT HIGH ERROR ...6968
FAILURE CODE [CA2556] GRID HTR RELAY VOLT LOW ERROR ...6970
FAILURE CODE [D110KB] BATTERY RELAY DRIVE S/C...6972
FAILURE CODE [DA25KP] 5V SENSOR 1 POWER ABNORMALITY ...6974
FAILURE CODE [DA2RMC] PUMP COMM. ABNORMALITY...6978
FAILURE CODE [DA2SKQ] MODEL SELECTION ABNORMALITY...6980
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3 ...6983
FAILURE CODE [DAFRMC] CAN DISCON (MONITOR DETECTED) ...6986
FAILURE CODE [DHPAMA] F PUMP PRESS SENSOR ABNORMALITY ...6988
FAILURE CODE [DHPBMA] R PUMP PRESS SENSOR ABNORMALITY...6990
FAILURE CODE [DHS3MA] ARM CURL PPC SEN. ABNORMALITY...6992
FAILURE CODE [DHS4MA] BUCKET CURL PPC PRESS SENSOR ABNORMALITY ...6994
FAILURE CODE [DW43KA] TRAVEL SPEED SOL. DISC...6996
FAILURE CODE [DW43KB] TRAVEL SPEED SOL. S/C...6998
FAILURE CODE [DW45KA] SWING BRAKE SOL. DISC. ...7000
FAILURE CODE [DW45KB] SWING BRAKE SOL. S/C...7004
FAILURE CODE [DW91KA] TRAVEL JUNCTION SOL. DISC...7006
FAILURE CODE [DW91KB] TRAVEL JUNCTION SOL. S/C...7008
FAILURE CODE [DWJ0KA] MERGE-DIVIDER SOL. DISC. ...7010
FAILURE CODE [DWJ0KB] MERGE-DIVIDER SOL. S/C...7012
FAILURE CODE [DWK0KA] 2-STAGE RELIEF SOL. DISC...7014
FAILURE CODE [DWK0KB] 2-STAGE RELIEF SOL. S/C...7016
FAILURE CODE [DXA0KA] PC-EPC SOL. DISC...7018
FAILURE CODE [DXA0KB] PC-EPC SOL. S/C...7020
FAILURE CODE [DXE0KA] LS-EPC SOL. DISC...7022
FAILURE CODE [DXE0KB] LS-EPC SOL. S/C...7024
FAILURE CODE [DXE4KA] SERVICE CURRENT EPC DISC...7026
FAILURE CODE [DXE4KB] SERVICE CURRENT EPC S/C...7027
FAILURE CODE [DY20KA] WIPER WORKING ABNORMALITY ...7028
FAILURE CODE [DY20MA] WIPER PARKING ABNORMALITY ...7030
FAILURE CODE [DY2CKB] WASHER DRIVE SHORT ...7032
FAILURE CODE [DY2DKB] WIPER DRIVE (FOR) SHORT...7034
FAILURE CODE [DY2EKB] WIPER DRIVE (REV) SHORT ...7036
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ...7039
BEFORE CARRYING OUT TROUBLESHOOTING OF ELECTRICAL SYSTEM...7042
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...7044
E-1 ENGINE DOES NOT START...7045
E-2 AUTO-DECELERATOR DOES NOT OPERATE ...7048
E-3 AUTOMATIC WARMING-UP SYSTEM DOES NOT OPERATE ...7050
E-4 PREHEATER DOES NOT OPERATE ...7052
E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE...7054
E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE...7056
E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL ...7058
E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS...7060
E-9 CONTENTS OF DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE...7060
E-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUNNING...7061
E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY ...7062
E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...7064
E-13 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY...7065
E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY...7066
E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTHING...7068
E-16 WINDSHIELD WIPER AND WINDOW WASHER DO NOT OPERATE ...7070
E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY ...7074
E-18 MONITORING FUNCTION FAILS TO DISPLAY “ BOOM RAISE ” NORMALLY ...7076
E-19 MONITORING FUNCTION FAILS TO DISPLAY “ BOOM LOWER ” NORMALLY ...7078
E-20 MONITORING FUNCTION FAILS TO DISPLAY “ ARM IN ” NORMALLY ...7080
E-21 MONITORING FUNCTION FAILS TO DISPLAY “ ARM OUT ” NORMALLY ...7082
E-22 MONITORING FUNCTION FAILS TO DISPLAY “ BUCKET CURL ” NORMALLY ...7084
E-23 MONITORING FUNCTION FAILS TO DISPLAY “ BUCKET DUMP ” NORMALLY ...7086
E-24 MONITORING FUNCTION FAILS TO DISPLAY “ SWING ” NORMALLY...7088
E-25 MONITORING FUNCTION FAILS TO DISPLAY “ TRAVEL ” NORMALLY ...7090
E-26 MONITORING FUNCTION FAILS TO DISPLAY “ TRAVEL DIFFERENTIAL PRESSURE ” NORMALLY ...7092
E-27 MONITORING FUNCTION FAILS TO DISPLAY “ SERVICE ” NORMALLY...7094
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ...7096
E-29 AIR CONDITIONER DOES NOT OPERATE...7098
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING ...7100
E-31 HORN DOES NOT SOUND...7102
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ...7105
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM ...7108
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...7110
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW...7112
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS ...7114
H-3 NO WORK EQUIPMENT, SWING OR TRAVEL MOVE...7115
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...7115
H-5 AUTO-DECELERATOR DOES NOT WORK...7116
H-6 FINE CONTROL MODE DOES NOT FUNCTION OR RESPONDS SLOW ...7116
H-7 BOOM MOVES SLOWLY OR LACKS POWER ...7117
H-8 ARM MOVES SLOWLY OR LACKS POWER...7118
H-9 BUCKET MOVES SLOWLY OR LACKS POWER...7119
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION ...7119
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT...7120
H-12 WORK EQUIPMENT HAS BIG TIME LAG...7122
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT...7122
H-14 POWER MAX. SWITCH DOES NOT OPERATE...7123
H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY ...7123
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY...7124
H-17 IN SWING + TRAVEL OPERATION, TRAVEL SPEED DROPS SHARPLY...7124
H-18 MACHINE SWERVES IN TRAVEL...7125
H-19 MACHINE TRAVELS SLOWLY ...7126
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER...7127
H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST...7128
H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)...7129
H-23 MACHINE DOES NOT SWING...7130
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW ...7132
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING...7134
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING ...7135
H-27 LARGE SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING...7135
H-28 SWING HYDRAULIC DRIFT IS TOO BIG ...7136
TROUBLESHOOTING OF ENGINE (S-MODE) ...7139
METHOD OF USING TROUBLESHOOTING CHART...7141
S-1 STARTING PERFORMANCE IS POOR...7144
S-2 ENGINE DOES NOT START...7145
S-3 ENGINE DOES NOT PICK UP SMOOTHLY ...7148
S-4 ENGINE STOPS DURING OPERATIONS ...7149
S-5 ENGINE DOES NOT ROTATE SMOOTHLY...7150
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) ...7151
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...7152
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) ...7153
S-9 OIL BECOMES CONTAMINATED QUICKLY...7154
S-10 FUEL CONSUMPTION IS EXCESSIVE...7155
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ...7156
S-12 OIL PRESSURE DROPS...7157
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)...7158
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) ...7159
S-15 ABNORMAL NOISE IS MADE...7160
S-16 VIBRATION IS EXCESSIVE...7161
50 DISASSEMBLY AND ASSEMBLY...0
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY...7163
HOW TO READ THIS MANUAL...7164
COATING MATERIALS LIST...7166
SPECIAL TOOLS LIST...7169
SKETCHES OF SPECIAL TOOLS...7173
ENGINE AND COOLING SYSTEM...7177
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY...7178
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...7181
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL...7183
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...7188
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...7200
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...7202
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY...7204
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY...7205
POWER TRAIN...7211
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY...7212
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY...7213
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...7221
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY ...7222
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY...7229
UNDERCARRIAGE AND FRAME...7231
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER...7232
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...7233
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY...7234
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ...7237
REMOVAL AND INSTALLATION OF SPROCKET...7239
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY...7240
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY...7241
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY...7243
HYDRAULIC SYSTEM ...7245
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY...7246
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY...7248
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY...7249
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY...7251
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY...7254
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY...7256
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT...7258
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY...7259
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...7260
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...7261
WORK EQUIPMENT...7267
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...7268
CAB AND ITS ATTACHMENTS ...7273
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...7274
REMOVAL AND INSTALLATION OF OPERATOR CAB GLASS (STUCK GLASS)...7277
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY...7287
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY...7294
ELECTRICAL SYSTEM...7299
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...7300
REMOVAL AND INSTALLATION OF KOMTRAX COMMUNICATION MODEM ASSEMBLY...7303
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY...7304
REMOVAL AND INSTALLATION OF PUMP CONTROLLER ASSEMBLY...7306
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER...7308
90 DIAGRAMS AND DRAWINGS...0
HYDRAULIC DIAGRAMS AND DRAWINGS...7311
HYDRAULIC CIRCUIT DIAGRAM...7313
ELECTRICAL DIAGRAMS AND DRAWINGS...7316
ELECTRICAL CIRCUIT DIAGRAM...7318
CONNECTOR ARRANGEMENT DIAGRAM...7319
SEN01983-04 - Hydraulic Excavator PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual...7326
COVER...7326
00 Index and foreword...0
Index...7328
Composition of shop manual...7329
Table of contents...7331
Foreword and general information...7340
Safety notice...7341
How to read the shop manual...7346
Explanation of terms for maintenance standard...7348
Handling of electric equipment and hydraulic component...7350
Handling of connectors newly used for engines...7359
How to read electric wire code...7362
Precautions when carrying out operation...7365
Method of disassembling and connecting push-pull type coupler...7368
Standard tightening torque table...7371
Conversion table...7375
01 Specification...0
Specification and technical data...7382
Specification dimension drawings...7383
Dimensions...7383
Working ranges...7384
Specifications...7385
Weight table...7391
Table of fuel, coolant and lubricants...7393
10 Structure, function and maintenance standard...0
Engine and cooling system...7396
Engine related parts...7397
Radiator, oil cooler and aftercooler...7398
Power train...7400
Power train...7401
Swing circle...7402
Swing machinery...7403
Final drive...7405
Sprocket...7407
Undercarriage and frame...7410
Track frame and recoil spring...7411
Idler...7413
Carrier roller...7415
Track roller...7416
Track shoe...7417
Hydraulic system, Part 1...7422
Hydraulic equipment layout drawing...7423
Hydraulic tank and filter...7425
Hydraulic pump...7427
Hydraulic system, Part 2...7452
Control valve...7453
CLSS...7465
Outline of CLSS...7465
Basic principle...7466
Functions and operation by valve...7469
Hydraulic circuit diagram and the name of valves...7469
Unload valve...7471
Introduction of LS pressure...7473
LS bypass plug...7474
Pressure compensation valve...7475
Pressure compensation valve inner shuttle valve...7478
Boom regeneration circuit...7480
Arm regeneration circuit...7482
Merge-divider valve...7484
LS select valve...7486
Self pressure reducing valve...7487
Travel junction valve...7490
Travel PPC shuttle valve...7492
Boom drift prevention valve...7494
Arm drift prevention valve...7497
Quick return valve...7501
Lift check valve...7503
Main relief valve...7504
2-stage safety-suction valve...7505
Variable pressure compensation valve...7507
Attachment circuit selector valve...7509
Hydraulic drift prevention valve...7511
Hydraulic system, Part 3...7518
Valve control...7519
PPC valve...7521
Solenoid valve...7543
PPC accumulator...7545
Return oil filter...7546
Center swivel joint...7547
Travel motor...7548
Swing motor...7560
Hydraulic cylinder...7569
Work equipment...7572
Work equipment...7573
Dimensions of components...7575
Cab and its attachments...7580
Air conditioner piping...7581
Electrical system...7584
Engine control...7585
Electronic control system...7594
Monitor system...7619
Sensor...7646
KOMTRAX terminal system...7649
20 Standard value table...0
Standard service value table...7652
Standard value table for engine related parts...7653
Standard value table for chassis related parts...7654
30 Testing and adjusting...0
Testing and adjusting, Part 1...7666
Tools for testing, adjusting and troubleshooting...7668
Testing engine speed...7672
Testing air boost pressure...7673
Testing exhaust gas color...7674
Adjusting valve clearance...7676
Testing compression pressure...7678
Testing blow-by pressure...7682
Testing engine oil pressure...7683
Testing fuel pressure...7684
Handling during cylinder cut-out operation...7688
Handling during no injection cranking operation...7688
Testing fuel return rate and leakage...7689
Bleeding air from fuel circuit...7691
Checking fuel circuit for leakage...7692
Testing and adjusting air compressor belt tension...7693
Replacing fan belt...7694
Replacing alternator belt...7695
Testing clearance in swing circle bearings...7696
Testing and adjusting track shoe tension...7697
Testing and adjusting oil pressure in work equipment, swing and travel circuit...7698
Testing and adjusting control circuit oil pressure...7702
Testing and adjusting pump PC control circuit oil pressure...7703
Testing and adjusting pump LS control circuit oil pressure...7706
Testing solenoid valve output pressure...7711
Testing PPC valve output pressure...7715
Adjusting play of work equipment and swing PPC valves...7716
Inspecting locations of hydraulic drift of work equipment...7717
Releasing remaining pressure in hydraulic circuit...7719
Testing oil leakage amount...7719
Bleeding air from various parts...7722
Diode inspection procedures...7724
Testing and adjusting, Part 2...7726
Special functions of machine monitor...7727
Testing and adjusting, Part 3...7784
Handling voltage circuit of engine controller...7785
Preparation work for troubleshooting of electrical system...7786
Procedure for testing diodes...7790
Pm clinic service...7791
40 Troubleshooting...0
Failure code table and fuse locations...7798
Failure codes table...7799
Fuse locations...7802
General information on troubleshooting...7808
Points to remember when troubleshooting...7809
Sequence of events in troubleshooting...7810
Checks before troubleshooting...7811
Classification and troubleshooting steps...7812
Information in troubleshooting table...7813
Connection table for connector pin numbers...7818
T- branch box and T- branch adapter table...7854
Troubleshooting by failure code (Display of code), Part 1...7858
Failure code [A000N1] Eng. Hi Out of Std...7860
Failure code [AA10NX] Air cleaner Clogging...7861
Failure code [AB00KE] Charge Voltage Low...7863
Failure code [B@BAZG] Eng Oil Press. Low...7865
Failure code [B@BAZK] Eng Oil Level Low...7867
Failure code [B@BCNS] Eng. Water Overheat...7869
Failure code [B@BCZK] Eng Water Level Low...7871
Failure code [B@HANS] Hydr Oil Overheat...7873
Failure code [CA111] EMC Critical Internal Failure...7874
Failure code [CA115] Eng Ne and Bkup Speed Sens Error...7874
Failure code [CA122] Chg Air Press Sensor High Error...7875
Failure code [CA123] Chg Air Press Sensor Low Error...7877
Failure code [CA131] Throttle Sensor High Error...7879
Failure code [CA132] Throttle Sensor Low Error...7881
Failure code [CA144] Coolant Temp Sens High Error...7883
Failure code [CA145] Coolant Temp Sens Low Error...7885
Failure code [CA153] Chg Air Temp Sensor High Error...7887
Failure code [CA154] Chg Air Temp Sensor Low Error...7889
Failure code [CA187] Sens Supply 2 Volt Low Error...7891
Failure code [CA221] Ambient Press Sens High Error...7893
Failure code [CA222] Ambient Press Sens Low Error...7895
Failure code [CA227] Sens Supply 2 Volt High Error...7897
Failure code [CA234] Eng Overspeed...7898
Failure code [CA238] Ne Speed Sens Supply Volt Error...7899
Failure code [CA271] IMV/PCV1 Short Error...7900
Failure code [CA272] IMV/PCV1 Open Error...7901
Failure code [CA322] Inj #1 Open/Short Error...7903
Failure code [CA323] Inj #5 Open/Short Error...7905
Failure code [CA324] Inj #3 Open/Short Error...7907
Failure code [CA325] Inj #6 Open/Short Error...7909
Failure code [CA331] Inj #2 Open/Short Error...7911
Failure code [CA332] Inj #4 Open/Short Error...7913
Troubleshooting by failure code (Display of code), Part 2...7916
Failure code [CA342] Calibration Code Incompatibility...7918
Failure code [CA351] Injectors Drive Circuit Error...7919
Failure code [CA352] Sens Supply 1 Volt Low Error...7921
Failure code [CA386] Sens Supply 1 Volt High Error...7923
Failure code [CA428] Water in Fuel Sensor High Error...7925
Failure code [CA429] Water in Fuel Sensor Low Error...7927
Failure code [CA441] Battery Voltage Low Error...7929
Failure code [CA442] Battery Voltage High Error...7931
Failure code [CA449] Rail Press Very High Error...7933
Failure code [CA451] Rail Press Sensor High Error...7937
Failure code [CA452] Rail Press Sensor Low Error...7939
Failure code [CA553] Rail Press High Error...7941
Failure code [CA559] Rail Press Low Error...7942
Failure code [CA689] Eng Ne Speed Sensor Error...7944
Failure code [CA731] Eng Bkup Speed Sens Phase Error...7946
Failure code [CA757] All Persistent Data Lost Error...7947
Failure code [CA778] Eng Bkup Speed Sensor Error...7949
Failure code [CA1633] KOMNET Datalink Timeout Error...7951
Failure code [CA2185] Throt Sens Sup Volt High Error...7953
Failure code [CA2186] Throt Sens Sup Volt Low Error...7954
Failure code [CA2249] Rail Press Very Low Error...7955
Failure code [CA2265] Electric Lift Pump High Error...7957
Failure code [CA2266] Electric Lift Pump Low Error...7959
Failure code [CA2555] Grid Htr Relay Volt High Error...7961
Failure code [CA2556] Grid Htr Relay Volt Low Error...7963
Failure code [D110KB] Battery Relay Drive S/C...7965
Failure code [D196KA] Service Return Relay Disc...7967
Failure code [D196KB] Service Return Relay S/C...7969
Failure code [DA25KP] 5V sensor 1 power abnormality...7971
Failure code [DA2RMC] Pump Comm. Abnormality...7975
Failure code [DA2SKQ] Model Selection Abnormality...7977
Troubleshooting by failure code (Display of code), Part 3...7980
Failure code [DAFRMC] CAN discon (Monitor detected)...7983
Failure code [DHPAMA] F Pump Press Sensor Abnormality...7985
Failure code [DHPBMA] R Pump Press Sensor Abnormality...7987
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality...7989
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality...7991
Failure code [DW43KA] Travel Speed Sol. Disc...7993
Failure code [DW43KB] Travel Speed Sol. S/C...7995
Failure code [DW45KA] Swing Brake Sol. Disc...7997
Failure code [DW45KB] Swing Brake Sol. S/C...8001
Failure code [DW91KA] Travel Junction Sol. Disc...8003
Failure code [DW91KB] Travel Junction Sol. S/C...8005
Failure code [DWJ0KA] Merge-divider Sol. Disc...8007
Failure code [DWJ0KB] Merge-divider Sol. S/C...8009
Failure code [DWK0KA] 2-stage Relief Sol. Disc...8011
Failure code [DWK0KB] 2-stage Relief Sol. S/C...8013
Failure code [DXA0KA] PC-EPC Sol. Disc...8015
Failure code [DXA0KB] PC-EPC Sol. S/C...8017
Failure code [DXE0KA] LS-EPC Sol. Disc...8019
Failure code [DXE0KB] LS-EPC Sol. S/C...8021
Failure code [DXE4KA] Service Current EPC Disc...8023
Failure code [DXE4KB] Service Current EPC S/C...8024
Failure code [DY20KA] Wiper Working Abnormality...8025
Failure code [DY20MA] Wiper Parking Abnormality...8027
Failure code [DY2CKB] Washer Drive Short...8029
Failure code [DY2DKB] Wiper Drive (For) Short...8031
Failure code [DY2EKB] Wiper Drive (Rev) Short...8033
Troubleshooting of electrical system (E-mode)...8036
Before carrying out troubleshooting of electrical system...8039
Information contained in troubleshooting table...8041
E-1 Engine does not start...8042
E-2 Auto-decelerator does not operate...8045
E-3 Automatic warming-up system does not operate...8047
E-4 Preheater does not operate...8049
E-5 All work equipment, swing, and travel mechanism do not move...8051
E-6 Power maximizing function does not operate...8053
E-7 Machine monitor does not display at all...8055
E-8 Machine monitor does not display some items...8057
E-9 Contents of display by machine monitor are different from applicable machine...8057
E-10 Fuel level monitor was lighted in red while engine running...8058
E-11 Engine coolant temperature gauge does not indicate normally...8059
E-12 Hydraulic oil temperature gauge does not indicate normally...8061
E-13 Fuel level gauge does not indicate normally...8062
E-14 Swing lock monitor does not indicate normally...8063
E-15 When monitor switch is operated, monitor displays nothing...8065
E-16 Windshield wiper and window washer do not operate...8067
E-17 Machine push-up function does not operate normally...8071
E-18 Monitoring function fails to display “boom raise” normally...8073
E-19 Monitoring function fails to display “boom lower” normally...8075
E-20 Monitoring function fails to display “arm IN” normally...8077
E-21 Monitoring function fails to display “arm OUT” normally...8079
E-22 Monitoring function fails to display “bucket CURL” normally...8081
E-23 Monitoring function fails to display “bucket DUMP” normally...8083
E-24 Monitoring function fails to display “swing” normally...8085
E-25 Monitoring function fails to display “travel” normally...8087
E-26 Monitoring function fails to display “travel differential pressure” normally...8089
E-27 Monitoring function fails to display “service” normally...8091
E-28 KOMTRAX system does not operate normally...8093
E-29 Air conditioner does not operate...8095
E-30 Travel alarm does not sound or does not stop sounding...8097
E-31 Horn does not sound...8099
Troubleshooting of hydraulic and mechanical system (H-mode)...8102
System chart for hydraulic and mechanical system...8105
Information contained in troubleshooting table...8107
H-1 All work equipment lack power, or travel and swing speeds are slow...8109
H-2 Engine speed sharply drops or engine stalls...8111
H-3 No work equipment, swing or travel move...8112
H-4 Abnormal noise is heard from around hydraulic pump...8112
H-5 Auto-decelerator does not work...8113
H-6 Fine control mode does not function or responds slow...8113
H-7 Boom moves slowly or lacks power...8114
H-8 Arm moves slowly or lacks power...8115
H-9 Bucket moves slowly or lacks power...8116
H-10 Work equipment does not move in its single operation...8116
H-11 Work equipment has a bit too fast hydraulic drift...8117
H-12 Work equipment has big time lag...8119
H-13 Other work equipment moves when relieving single circuit...8119
H-14 Power max. switch does not operate...8120
H-15 In compound operation, work equipment with larger load moves slowly...8120
H-16 In swing + boom RAISE operation, boom moves slowly...8121
H-17 In swing + travel operation, travel speed drops sharply...8121
H-18 Machine swerves in travel...8122
H-19 Machine travels slowly...8123
H-20 Machine cannot be easily steered or lacks power...8124
H-21 Travel speed does not shift, or it is too slow or fast...8125
H-22 Track shoe does not turn (on one side only)...8126
H-23 Machine does not swing...8127
H-24 Swing acceleration is poor, or swing speed is slow...8129
H-25 Excessive overrun when stopping swing...8131
H-26 There is big shock when stopping swing...8132
H-27 Large sound is made when upper structure stops swinging...8132
H-28 Swing hydraulic drift is too big...8133
Troubleshooting of engine (S-mode)...8136
Method of using troubleshooting chart...8138
S-1 Starting performance is poor...8141
S-2 Engine does not start...8142
S-3 Engine does not pick up smoothly...8145
S-4 Engine stops during operations...8146
S-5 Engine does not rotate smoothly...8147
S-6 Engine lacks output (or lacks power)...8148
S-7 Exhaust smoke is black (incomplete combustion)...8149
S-8 Oil consumption is excessive (or exhaust smoke is blue)...8150
S-9 Oil becomes contaminated quickly...8151
S-10 Fuel consumption is excessive...8152
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...8153
S-12 Oil pressure drops...8154
S-13 Oil level rises (Entry of coolant or fuel)...8155
S-14 Coolant temperature becomes too high (overheating)...8156
S-15 Abnormal noise is made...8157
S-16 Vibration is excessive...8158
50 Disassembly and assembly...0
General information on disassembly and assembly...8160
How to read this manual...8161
Coating materials list...8163
Special tools list...8166
Sketches of special tools...8170
Engine and cooling system...8174
Removal and installation of fuel supply pump assembly...8175
Removal and installation of engine front seal...8178
Removal and installation of engine rear seal...8180
Removal and installation of cylinder head assembly...8185
Removal and installation of radiator assembly...8197
Removal and installation of hydraulic oil cooler assembly...8199
Removal and installation of aftercooler assembly...8201
Removal and installation of engine and hydraulic pump assembly...8202
Power train...8208
Removal and installation of final drive assembly...8209
Disassembly and assembly of final drive assembly...8210
Removal and installation of swing motor and swing machinery assembly...8218
Disassembly and assembly of swing motor and swing machinery assembly...8219
Removal and installation of swing circle assembly...8226
Undercarriage and frame...8228
Disassembly and assembly of carrier roller...8229
Disassembly and assembly of track roller assembly...8230
Disassembly and assembly of idler assembly...8231
Disassembly and assembly of recoil spring...8234
Removal and installation of sprocket...8236
Expansion and installation of track shoe assembly...8237
Removal and installation of revolving frame assembly...8238
Removal and installation of counterweight assembly...8240
Hydraulic system...8242
Removal and installation of center swivel joint assembly...8243
Disassembly and assembly of center swivel joint assembly...8245
Removal and installation of hydraulic tank assembly...8246
Removal and installation of control valve assembly...8248
Disassembly and assembly of control valve assembly...8251
Removal and installation of hydraulic pump assembly...8253
Removal and installation of oil seal in hydraulic pump input shaft...8255
Disassembly and assembly of work equipment PPC valve assembly...8256
Disassembly and assembly of travel PPC valve assembly...8257
Disassembly and assembly of hydraulic cylinder assembly...8258
Work equipment...8264
Removal and installation of work equipment assembly...8265
Cab and its attachments...8270
Removal and installation of operator's cab assembly...8271
Removal and installation of operator cab glass (stuck glass)...8274
Removal and installation of front window assembly...8284
Removal and installation of floor frame assembly...8291
Electrical system...8296
Removal and installation of air conditioner unit assembly...8297
Removal and installation of KOMTRAX communication modem assembly...8300
Removal and installation of monitor assembly...8301
Removal and installation of pump controller assembly...8303
Removal and installation of engine controller...8305
90 Diagrams and drawings...0
Hydraulic diagrams and drawings...8308
Hydraulic circuit diagram...8310
Electrical diagrams and drawings...8313
Electrical circuit diagram...8315
Connector arrangement diagram...8316
SEN01983-15 - Hydraulic Excavator PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual...8323
COVER...8323
00 Index and foreword...0
Index...8325
Composition of shop manual...8326
Table of contents...8328
Foreword and general information...8337
Safety notice...8338
How to read the shop manual...8343
Explanation of terms for maintenance standard...8345
Handling of electric equipment and hydraulic component...8347
Handling of connectors newly used for engines...8356
How to read electric wire code...8359
Precautions when carrying out operation...8362
Method of disassembling and connecting push-pull type coupler...8365
Standard tightening torque table...8368
Conversion table...8372
01 Specification...0
Specification and technical data...8379
Specification dimension drawings...8380
Dimensions...8380
Working ranges...8381
Specifications...8382
Weight table...8388
Table of fuel, coolant and lubricants...8390
10 Structure, function and maintenance standard...0
Engine and cooling system...8393
Engine related parts...8394
Radiator, oil cooler and aftercooler...8395
Power train...8397
Power train...8398
Swing circle...8399
Swing machinery...8400
Final drive...8402
Sprocket...8404
Undercarriage and frame...8407
Track frame and recoil spring...8408
Idler...8410
Carrier roller...8412
Track roller...8413
Track shoe...8414
Hydraulic system, Part 1...8419
Hydraulic equipment layout drawing...8420
Hydraulic tank and filter...8422
Hydraulic pump...8424
Hydraulic system, Part 2...8449
Control valve...8450
CLSS...8462
Functions and operation by valve...8466
Merge-divider valve...8481
Attachment circuit selector valve...8506
Hydraulic drift prevention valve...8508
Hydraulic system, Part 3...8515
Valve control...8516
PPC valve...8518
Solenoid valve...8540
PPC accumulator...8542
Return oil filter...8543
Center swivel joint...8544
Travel motor...8545
Swing motor...8557
Hydraulic cylinder...8566
Work equipment...8569
Work equipment...8570
Dimensions of components...8572
Cab and its attachments...8577
Air conditioner piping...8578
Electrical system...8581
Engine control...8582
Electronic control system...8591
Monitor system...8616
Sensor...8643
KOMTRAX system...8646
20 Standard value table...0
Standard service value table...8649
Standard value table for engine related parts...8650
Standard value table for chassis related parts...8651
30 Testing and adjusting...0
Testing and adjusting, Part 1...8663
Tools for testing, adjusting and troubleshooting...8665
Sketches of special tools...8669
Testing engine speed...8670
Testing air boost pressure...8671
Testing exhaust gas color...8672
Adjusting valve clearance...8674
Testing compression pressure...8676
Testing blow-by pressure...8680
Testing engine oil pressure...8681
Testing fuel pressure...8682
Handling during cylinder cut-out operation...8687
Handling during no injection cranking operation...8687
Testing fuel return rate and leakage...8688
Bleeding air from fuel circuit...8690
Checking fuel circuit for leakage...8691
Testing and adjusting air compressor belt tension...8692
Replacing fan belt...8693
Replacing alternator belt...8694
Testing clearance in swing circle bearings...8695
Testing and adjusting track shoe tension...8696
Testing and adjusting oil pressure in work equipment, swing and travel circuit...8697
Testing and adjusting control circuit oil pressure...8701
Testing and adjusting pump PC control circuit oil pressure...8702
Testing and adjusting pump LS control circuit oil pressure...8705
Testing solenoid valve output pressure...8710
Testing PPC valve output pressure...8714
Adjusting play of work equipment and swing PPC valves...8715
Inspecting locations of hydraulic drift of work equipment...8716
Releasing remaining pressure in hydraulic circuit...8718
Testing oil leakage amount...8718
Bleeding air from various parts...8721
Diode inspection procedures...8723
Testing and adjusting, Part 2...8729
Special functions of machine monitor...8730
Testing and adjusting, Part 3...8787
Handling voltage circuit of engine controller...8788
Preparation work for troubleshooting of electrical system...8789
Procedure for testing diodes...8793
Pm clinic service...8794
40 Troubleshooting...0
Failure code table and fuse locations...8801
Failure codes table...8802
Fuse locations...8805
General information on troubleshooting...8811
Points to remember when troubleshooting...8812
Sequence of events in troubleshooting...8813
Checks before troubleshooting...8814
Classification and troubleshooting steps...8815
Information in troubleshooting table...8816
Connection table for connector pin numbers...8821
T- branch box and T- branch adapter table...8857
Troubleshooting by failure code (Display of code), Part 1...8861
Failure code [989L00] Engine Controller Lock Caution 1...8863
Failure code [989M00] Engine Controller Lock Caution 2...8863
Failure code [989N00] Engine Controller Lock Caution 3...8864
Failure code [AA10NX] Air cleaner Clogging...8866
Failure code [AB00KE] Charge Voltage Low...8868
Failure code [B@BAZG] Eng Oil Press. Low...8870
Failure code [B@BAZK] Eng Oil Level Low...8872
Failure code [B@BCNS] Eng. Water Overheat...8874
Failure code [B@BCZK] Eng Water Level Low...8876
Failure code [B@HANS] Hydr Oil Overheat...8878
Failure code [CA111] EMC Critical Internal Failure...8879
Failure code [CA115] Eng Ne and Bkup Speed Sens Error...8879
Failure code [CA122] Chg Air Press Sensor High Error...8880
Failure code [CA123] Chg Air Press Sensor Low Error...8882
Failure code [CA131] Throttle Sensor High Error...8884
Failure code [CA132] Throttle Sensor Low Error...8886
Failure code [CA144] Coolant Temp Sens High Error...8888
Failure code [CA145] Coolant Temp Sens Low Error...8890
Failure code [CA153] Chg Air Temp Sensor High Error...8892
Failure code [CA154] Chg Air Temp Sensor Low Error...8894
Failure code [CA155] Chg Air Temp High Speed Derate...8896
Failure code [CA187] Sens Supply 2 Volt Low Error...8898
Failure code [CA221] Ambient Press Sens High Error...8900
Failure code [CA222] Ambient Press Sens Low Error...8902
Failure code [CA227] Sens Supply 2 Volt High Error...8904
Failure code [CA234] Eng Overspeed...8905
Failure code [CA238] Ne Speed Sens Supply Volt Error...8906
Failure code [CA271] IMV/PCV1 Short Error...8907
Failure code [CA272] IMV/PCV1 Open Error...8908
Failure code [CA281] Pump Press Balance Error...8910
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error...8911
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error...8913
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error...8915
Failure code [CA325] Inj #6 (L/B#6) Open/Short Error...8917
Failure code [CA331] Inj #2 (L/B#2) Open/Short Error...8919
Failure code [CA332] Inj #4 (L/B#4) Open/Short Error...8921
Troubleshooting by failure code (Display of code), Part 2...8925
Failure code [CA342] Calibration Code Incompatibility...8927
Failure code [CA351] Injectors Drive Circuit Error...8928
Failure code [CA352] Sens Supply 1 Volt Low Error...8930
Failure code [CA386] Sens Supply 1 Volt High Error...8932
Failure code [CA428] Water in Fuel Sensor High Error...8934
Failure code [CA429] Water in Fuel Sensor Low Error...8936
Failure code [CA435] Eng Oil Press Sw Error...8938
Failure code [CA441] Battery Voltage Low Error...8940
Failure code [CA442] Battery Voltage High Error...8942
Failure code [CA449] Rail Press Very High Error...8944
Failure code [CA451] Rail Press Sensor High Error...8948
Failure code [CA452] Rail Press Sensor Low Error...8950
Failure code [CA488] Chg Air Temp High Torque Derate...8952
Failure code [CA553] Rail Press High Error...8952
Failure code [CA559] Rail Press Low Error...8954
Failure code [CA689] Eng Ne Speed Sensor Error...8956
Failure code [CA731] Eng Bkup Speed Sens Phase Error...8958
Failure code [CA757] All Persistent Data Lost Error...8960
Failure code [CA778] Eng Bkup Speed Sensor Error...8962
Failure code [CA1633] KOMNET Datalink Timeout Error...8964
Failure code [CA2185] Throt Sens Sup Volt High Error...8966
Failure code [CA2186] Throt Sens Sup Volt Low Error...8967
Failure code [CA2249] Rail Press Very Low Error...8968
Failure code [CA2265] Fuel Feed Pump Open Error...8970
Failure code [CA2266] Fuel Feed Pump Short Error...8972
Failure code [CA2311] IMV Solenoid Error...8974
Failure code [CA2555] Grid Htr Relay Volt Low Error...8976
Failure code [CA2556] Grid Htr Relay Volt High Error...8978
Failure code [D110KB] Battery Relay Drive S/C...8980
Failure code [D19JKZ] Personal Code Relay Abnormality...8982
Failure code [D862KA] GPS Antenna Discon...8984
Failure code [DA22KK] Pump Solenoid Power Low Error...8985
Failure code [DA25KP] 5V sensor 1 power abnormality...8987
Failure code [DA29KQ] Model Selection Abnormality...8990
Failure code [DA2RMC] Pump Comm. Abnormality...8992
Failure code [DAF8KB] Short circuit in camera power supply...8994
Failure code [DAFGMC] GPS Module Error...8996
Troubleshooting by failure code (Display of code), Part 3...8999
Failure code [DAFRMC] CAN discon (Monitor detected)...9002
Failure code [DGH2KB] Hydr Oil Sensor Short...9004
Failure code [DHPAMA] F Pump Press Sensor Abnormality...9006
Failure code [DHPBMA] R Pump Press Sensor Abnormality...9008
Failure code [DHS3MA] Arm Curl PPC Sensor Abnormality...9010
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality...9012
Failure code [DHX1MA] Overload Sensor Abnormality (Analog)...9014
Failure code [DW43KA] Travel Speed Sol. Open Circuit...9016
Failure code [DW43KB] Travel Speed Sol. Short Circuit...9018
Failure code [DW45KA] Swing Brake Sol. Open Circuit...9020
Failure code [DW45KB] Swing Brake Sol. Short Circuit...9024
Failure code [DW91KA] Travel Junction Sol. Open Circuit...9026
Failure code [DW91KB] Travel Junction Sol. Short Circuit...9028
Failure code [DWA2KA] Attachment Sol Open Circuit...9030
Failure code [DWA2KB] Attachment Sol Short Circuit...9031
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit...9032
Failure code [DWJ0KB] Merge-divider Sol. Short Circuit...9034
Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit...9036
Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit...9038
Failure code [DXA0KA] PC-EPC Sol. Open Circuit...9040
Failure code [DXA0KB] PC-EPC Sol. Short Circuit...9042
Failure code [DXE0KA] LS-EPC Sol. Open Circuit...9044
Failure code [DXE0KB] LS-EPC Sol. Short Circuit...9046
Failure code [DXE4KA] Service Current EPC Open Circuit...9048
Failure code [DXE4KB] Service Current EPC Short Circuit...9049
Failure code [DY20KA] Wiper Working Abnormality...9050
Failure code [DY20MA] Wiper Parking Abnormality...9052
Failure code [DY2CKA] Washer Drive Open Circuit...9054
Failure code [DY2CKB] Washer Drive Short Circuit...9056
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit...9058
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...9060
Troubleshooting of electrical system (E-mode)...9063
Before carrying out troubleshooting of electrical system...9066
Information contained in troubleshooting table...9068
E-1 Engine does not start...9069
E-2 Auto-decelerator does not operate...9072
E-3 Automatic warming-up system does not operate...9074
E-4 Preheater does not operate...9076
E-5 All work equipment, swing, and travel mechanism do not move...9078
E-6 Power maximizing function does not operate...9080
E-7 Machine monitor does not display at all...9082
E-8 Machine monitor does not display some items...9084
E-9 Contents of display by machine monitor are different from applicable machine...9084
E-10 Fuel level monitor was lighted in red while engine running...9085
E-11 Engine coolant temperature gauge does not indicate normally...9086
E-12 Hydraulic oil temperature gauge does not indicate normally...9088
E-13 Fuel level gauge does not indicate normally...9089
E-14 Swing lock monitor does not indicate normally...9090
E-15 When monitor switch is operated, monitor displays nothing...9092
E-16 Windshield wiper and window washer do not operate...9094
E-17 Machine push-up function does not operate normally...9098
E-18 Monitoring function fails to display “boom raise” normally...9100
E-19 Monitoring function fails to display “boom lower” normally...9102
E-20 Monitoring function fails to display “arm IN” normally...9104
E-21 Monitoring function fails to display “arm OUT” normally...9106
E-22 Monitoring function fails to display “bucket CURL” normally...9108
E-23 Monitoring function fails to display “bucket DUMP” normally...9110
E-24 Monitoring function fails to display “swing” normally...9112
E-25 Monitoring function fails to display “travel” normally...9114
E-26 Monitoring function fails to display “travel differential pressure” normally...9116
E-27 Monitoring function fails to display “service” normally...9118
E-28 KOMTRAX system does not operate normally...9120
E-29 Air conditioner does not operate...9122
E-30 Travel alarm does not sound or does not stop sounding...9124
E-31 Horn does not sound...9126
Troubleshooting of hydraulic and mechanical system (H-mode)...9129
System chart for hydraulic and mechanical system...9132
Information contained in troubleshooting table...9134
H-1 All work equipment lack power, or travel and swing speeds are slow...9136
H-2 Engine speed sharply drops or engine stalls...9138
H-3 No work equipment, swing or travel move...9139
H-4 Abnormal noise is heard from around hydraulic pump...9139
H-5 Auto-decelerator does not work...9140
H-6 Fine control mode does not function or responds slow...9140
H-7 Boom moves slowly or lacks power...9141
H-8 Arm moves slowly or lacks power...9142
H-9 Bucket moves slowly or lacks power...9143
H-10 Work equipment does not move in its single operation...9143
H-11 Work equipment has a bit too fast hydraulic drift...9144
H-12 Work equipment has big time lag...9146
H-13 Other work equipment moves when relieving single circuit...9146
H-14 Power max. switch does not operate...9147
H-15 In compound operation, work equipment with larger load moves slowly...9147
H-16 In swing + boom RAISE operation, boom moves slowly...9148
H-17 In swing + travel operation, travel speed drops sharply...9148
H-18 Machine swerves in travel...9149
H-19 Machine travels slowly...9150
H-20 Machine cannot be easily steered or lacks power...9151
H-21 Travel speed does not shift, or it is too slow or fast...9152
H-22 Track shoe does not turn (on one side only)...9153
H-23 Machine does not swing...9154
H-24 Swing acceleration is poor, or swing speed is slow...9156
H-25 Excessive overrun when stopping swing...9158
H-26 There is big shock when stopping swing...9159
H-27 Large sound is made when upper structure stops swinging...9159
H-28 Swing hydraulic drift is too big...9160
Troubleshooting of engine (S-mode)...9163
Method of using troubleshooting chart...9165
S-1 Starting performance is poor...9168
S-2 Engine does not start...9169
S-3 Engine does not pick up smoothly...9172
S-4 Engine stops during operations...9173
S-5 Engine does not rotate smoothly...9174
S-6 Engine lacks output (or lacks power)...9175
S-7 Exhaust smoke is black (incomplete combustion)...9176
S-8 Oil consumption is excessive (or exhaust smoke is blue)...9177
S-9 Oil becomes contaminated quickly...9178
S-10 Fuel consumption is excessive...9179
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...9180
S-12 Oil pressure drops...9181
S-13 Oil level rises (Entry of coolant or fuel)...9182
S-14 Coolant temperature becomes too high (overheating)...9183
S-15 Abnormal noise is made...9184
S-16 Vibration is excessive...9185
50 Disassembly and assembly...0
General information on disassembly and assembly...9187
How to read this manual...9188
Coating materials list...9190
Special tools list...9193
Sketches of special tools...9196
Engine and cooling system...9201
Removal and installation of fuel supply pump assembly...9202
Removal and installation of engine front seal...9205
Removal and installation of engine rear seal...9208
Removal and installation of cylinder head assembly...9213
Removal and installation of radiator assembly...9226
Removal and installation of hydraulic oil cooler assembly...9228
Removal and installation of aftercooler assembly...9230
Removal and installation of aftercooler assembly...9231
Power train...9237
Removal and installation of final drive assembly...9238
Disassembly and assembly of final drive assembly...9239
Removal and installation of swing motor and swing machinery assembly...9247
Disassembly and assembly of swing motor and swing machinery assembly...9248
Removal and installation of swing circle assembly...9255
Undercarriage and frame...9257
Disassembly and assembly of carrier roller...9258
Disassembly and assembly of track roller assembly...9259
Disassembly and assembly of idler assembly...9260
Disassembly and assembly of recoil spring...9263
Removal and installation of sprocket...9265
Expansion and installation of track shoe assembly...9266
Removal and installation of revolving frame assembly...9268
Removal and installation of counterweight assembly...9270
Hydraulic system...9275
Removal and installation of center swivel joint assembly...9276
Disassembly and assembly of center swivel joint assembly...9278
Removal and installation of hydraulic tank assembly...9279
Removal and installation of control valve assembly...9281
Disassembly and assembly of control valve assembly...9284
Removal and installation of hydraulic pump assembly...9285
Removal and installation of oil seal in hydraulic pump input shaft...9287
Disassembly and assembly of work equipment PPC valve assembly...9288
Disassembly and assembly of travel PPC valve assembly...9290
Disassembly and assembly of hydraulic cylinder assembly...9293
Work equipment...9299
Removal and installation of work equipment assembly...9300
Cab and its attachments...9305
Removal and installation of operator's cab assembly...9306
Removal and installation of operator cab glass (stuck glass)...9309
Removal and installation of front window assembly...9319
Removal and installation of floor frame assembly...9326
Electrical system...9331
Removal and installation of air conditioner unit assembly...9332
Removal and installation of KOMTRAX communication modem assembly...9335
Removal and installation of monitor assembly...9336
Removal and installation of pump controller assembly...9338
Removal and installation of engine controller...9340
90 Diagrams and drawings...0
Hydraulic diagrams and drawings...9343
Hydraulic circuit diagram...9345
Electrical diagrams and drawings...9348
Electrical circuit diagram...9350
Connector list and sterogram...9355
TEN00055-02 - Hydraulic Excavator GALEO PC300-7, PC300LC-7, PC350-7, PC350LC-7 Operation & Maintenance Manual...9358
COVER...9358
FOREWORD...9359
FOREWORD...9360
SAFETY INFORMATION...9363
INTRODUCTION...9365
DIRECTIONS OF MACHINE...9365
BREAKING-IN OPERATION...9365
PRODUCT INFORMATION...9366
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE...9366
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...9366
SERVICE METER LOCATION...9367
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...9367
CONTENTS...9368
SAFETY...9372
SAFETY INFORMATION...9373
POSITION FOR ATTACHING SAFETY LABELS...9375
POSITION FOR ATTACHING SAFETY LABELS...9375
SAFETY LABELS...9376
SAFETY INFORMATION...9381
SAFETY RULES...9381
IF ABNORMALITIES ARE FOUND...9381
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...9381
FIRE EXTINGUISHER AND FIRST AID KIT...9381
SAFETY EQUIPMENT...9382
KEEP MACHINE CLEAN...9382
KEEP OPERATOR'S COMPARTMENT CLEAN...9382
LEAVING OPERATOR'S SEAT WITH LOCK...9382
HANDRAILS AND STEPS...9383
MOUNTING AND DISMOUNTING...9384
NO PERSONS ON ATTACHMENTS...9384
BURN PREVENTION...9384
FIRE PREVENTION AND EXPLOSION PREVENTION...9385
ACTION IF FIRE OCCURS...9386
WINDSHIELD WASHER FLUID...9386
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...9386
ATTACHMENT INSTALLATION...9386
ATTACHMENT COMBINATIONS...9387
CAB WIDOW GLASSES...9387
UNAUTHORIZED MODIFICATIONS...9387
SAFETY AT JOBSITE...9387
WORKING ON LOOSE GROUND...9388
DISTANCE TO HIGH VOLTAGE CABLES...9388
ENSURE GOOD VISIBILITY...9388
VENTILATION FOR ENCLOSED AREA...9389
SIGNALMAN'S SIGNAL AND SIGNS...9389
EMERGENCY EXIT FROM OPERATOR'S CAB...9389
ASBESTOS DUST HAZARD PREVENTION...9389
SAFETY MACHINE OPERATION...9390
STARTING ENGINE...9390
CHECKS BEFORE STARTING ENGINE...9390
SAFETY RULES FOR STARTING ENGINE...9391
STARTING ENGINE IN COLD WEATHER...9391
OPERATION...9392
CHECKS AFTER STARTING ENGINE...9392
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...9392
SAFETY RULES FOR TRAVELING...9393
TRAVELING ON SLOPES...9394
OPERATIONS ON SLOPES...9395
PROHIBITED OPERATIONS...9395
OPERATIONS ON SNOW...9397
PARKING MACHINE...9397
TRANSPORTATION...9398
SHIPPING THE MACHINE...9398
BATTERY...9399
BATTERY HAZARD PREVENTION...9399
STARTING ENGINE WITH BOOSTER CABLES...9400
TOWING...9401
SAFETY RULES FOR TOWING...9401
LIFTING OBJECTS WITH BUCKET...9402
SAFETY RULES FOR LIFTING OBJECTS...9402
SAFETY MAINTENANCE INFORMATION...9403
WARNING TAG...9403
KEEP WORK PLACE CLEAN AND TIDY...9403
APPOINT LEADER WHEN WORKING WITH OTHERS...9403
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...9404
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...9405
PROPER TOOLS...9405
ACCUMULATOR...9406
PERSONNEL...9406
ATTACHMENTS...9406
WORK UNDER THE MACHINE...9406
NOISE...9407
WHEN USING HAMMER...9407
WELDING WORKS...9407
REMOVING BATTERY TERMINALS...9407
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...9408
DO NOT DISASSEMBLE RECOIL SPRINGS...9408
SAFETY RULES FOR HIGH-PRESSURE OIL...9408
SAFETY HANDLING HIGH-PRESSURE HOSES...9409
WASTE MATERIALS...9409
AIR CONDITIONER MAINTENANCE...9409
COMPRESSED AIR...9409
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...9410
OPERATION...9411
GENERAL VIEW...9412
GENERAL VIEW OF MACHINE...9412
GENERAL VIEW CONTROLS AND GAUGES...9413
EXPLANATION OF COMPONENTS...9414
MACHINE MONITOR...9414
BASIC CHECK ITEMS...9417
SWITCHES...9438
CONTROL LEVERS, PEDALS...9444
CEILING WINDOW...9447
FRONT WINDOW...9448
EMERGENCY EXIT FROM OPERATOR'S CAB...9453
DOOR LOCK...9453
CAP, COVER WITH LOCK...9454
HOT AND COOL BOX...9455
MAGAZINE BOX...9455
ASHTRAY...9455
AIR CONDITIONER CONTROLS...9456
CAR RADIO...9470
FUSE...9476
FUSIBLELINK...9477
CONTROLLER (COMPUTER)...9478
TOOLBOX...9478
GREASE GUN HOLDER...9478
HANDLING ACCUMULATOR...9479
MACHINE OPERATIONS AND CONTROLS...9480
BEFORE STARTING ENGINE...9480
STARTING ENGINE...9495
AFTER STARTING ENGINE...9499
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)...9502
STOPPING THE ENGINE...9506
CHECK AFTER SHUT OFF ENGINE...9506
MACHINE OPERATION...9507
STEERING THE MACHINE...9511
SWINGING...9513
WORK EQUIPMENT CONTROLS AND OPERATIONS...9514
OPERATING WORKING MODE...9516
PROHIBITED OPERATIONS...9517
GENERAL OPERATION INFORMATION...9519
TRAVELING ON SLOPES...9520
ESCAPE FROM MUD...9522
RECOMMENDED APPLICATIONS...9523
REPLACEMENT AND INVERSION OF BUCKET...9525
PARKING MACHINE...9529
CHECK AFTER FINISHING WORK...9530
LOCKING...9531
TRANSPORTATION...9532
TRANSPORTATION PROCEDURE...9532
LOADING AND UNLOADING WITH TRAILER...9533
LIFTING MACHINE...9541
COLD WEATHER OPERATION...9543
COLD WEATHER OPERATION INFORMATION...9543
AFTER DAILY WORK COMPLETION...9546
AFTER COLD WEATHER SEASON...9546
LONG TERM STORAGE...9547
BEFORE STORAGE...9547
DURING STORAGE...9547
AFTER STORAGE...9548
TROUBLESHOOTING...9549
AFTER RUNNING OUT OF FUEL...9549
PHENOMENA THAT ARE NOT FAILURES...9549
TOWING THE MACHINE...9550
LIGHTWEIGHT TOWING HOLE...9551
SEVERE JOB CONDITION...9551
DISCHARGED BATTERY...9552
OTHER TROUBLE...9556
MAINTENANCE...9562
MAINTENANCE INFORMATION...9563
OUTLINE OF SERVICE...9566
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...9566
ELECTRIC SYSTEM MAINTENANCE...9570
HANDLING HYDRAULIC SYSTEM...9570
WEAR PARTS LIST...9572
RECOMMENDED FUEL, COOLANT AND LUBRICANTS...9573
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...9574
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...9575
TIGHTENING TORQUE SPECIFICATIONS...9576
TIGHTENING TORQUE LIST...9576
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...9577
SAFETY CRITICAL PARTS...9578
MAINTENANCE SCHEDULE...9579
MAINTENANCE SCHEDULE CHART...9579
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...9581
MAINTENANCE PROCEDURE...9582
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...9582
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)...9582
WHEN REQUIRED...9583
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...9583
CLEAN INSIDE OF COOLING SYSTEM...9588
CHECK AND TIGHTEN TRACK SHOE BOLTS...9591
CHECK AND ADJUST TRACK TENSION...9592
CHECK ELECTRICAL INTAKE AIR HEATER...9594
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...9595
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...9598
REPLACE BUCKET SIDE CUTTER, SHROUD...9599
ADJUST BUCKET CLEARANCE...9600
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...9601
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)...9602
WASHING WASHABLE FLOOR...9603
METHOD OF SETTING MACHINE ANGLE...9605
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...9608
CHECK BEFORE STARTING...9609
EVERY 50 HOURS MAINTENANCE...9610
LUBRICATING...9610
EVERY 250 HOURS MAINTENANCE...9611
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...9611
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...9612
CHECK LEVEL OF BATTERY ELECTROLYTE...9613
LUBRICATE SWING CIRCLE (2 PLACES)...9615
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...9616
EVERY 500 HOURS MAINTENANCE...9617
LUBRICATING...9617
REPLACE FUEL FILTER CARTRIDGE...9618
CHECK SWING PINION GREASE LEVEL, ADD GREASE...9619
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...9620
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS...9622
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...9623
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...9625
EVERY 1000 HOURS MAINTENANCE...9626
REPLACE HYDRAULIC FILTER ELEMENT...9626
CHANGE OIL IN SWING MACHINERY CASE...9628
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...9629
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...9629
CHECK PLAY OF TURBOCHARGER ROTOR...9629
REPLACE CORROSION RESISTOR CARTRIDGE...9629
CHECK FAN BELT TENSION AND REPLACE FAN BELT...9630
EVERY 2000 HOURS MAINTENANCE...9631
CHANGE OIL IN FINAL DRIVE CASE...9631
CLEAN HYDRAULIC TANK STRAINER...9632
CLEAN ENGINE BREATHER...9632
CLEAN, CHECK TURBOCHARGER...9633
CHECK ALTERNATOR, STARTING MOTOR...9633
CHECK ENGINE VALVE CLEARANCE, ADJUST...9633
CHECK VIBRATION DAMPER...9633
EVERY 4000 HOURS MAINTENENCE...9634
CHECK WATER PUMP...9634
EVERY 5000 HOURS MAINTENANCE...9635
CHANGE OIL IN HYDRAULIC TANK...9635
SPECIFICATIONS...9636
SPECIFICATIONS...9637
ATTACHMENTS AND OPTIONS...9639
GENERAL PRECAUTIONS...9640
PRECAUTIONS RELATED TO SAFETY...9640
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...9642
HANDLING BUCKET WITH HOOK...9643
CHECKING FOR DAMAGE TO BUCKET WITH HOOK...9643
PROHIBITED OPERATIONS...9643
MACHINES READY FOR ATTACHMENTS...9644
EXPLANATION OF COMPONENTS...9644
HYDRAULIC CIRCUIT...9647
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...9651
OPERATION...9653
LONG-TERM STORAGE...9655
SPECIFICATIONS...9655
ATTACHMENT GUIDE...9656
COMBINATIONS OF WORK EQUIPMENT...9656
SELECTING TRACK SHOE...9658
RECOMMENDED ATTACHMENT OPERATIONS...9659
HYDRAULIC BREAKER...9659
INDEX...9664
TEN00056-02 - Hydraulic Excavator GALEO PC300-7, PC300LC-7, PC350-7, PC350LC-7 Operation & Maintenance Manual...9667
COVER...9667
FOREWORD...9668
FOREWORD...9669
SAFETY INFORMATION...9672
INTRODUCTION...9674
DIRECTIONS OF MACHINE...9674
BREAKING-IN OPERATION...9674
PRODUCT INFORMATION...9675
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE...9675
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...9675
SERVICE METER LOCATION...9676
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...9676
CONTENTS...9677
SAFETY...9682
SAFETY INFORMATION...9683
POSITION FOR ATTACHING SAFETY LABELS...9685
POSITION FOR ATTACHING SAFETY LABELS...9685
SAFETY LABELS...9686
SAFETY INFORMATION...9691
SAFETY RULES...9691
IF ABNORMALITIES ARE FOUND...9691
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...9691
FIRE EXTINGUISHER AND FIRST AID KIT...9691
SAFETY EQUIPMENT...9692
KEEP MACHINE CLEAN...9692
KEEP OPERATOR'S COMPARTMENT CLEAN...9692
LEAVING OPERATOR'S SEAT WITH LOCK...9692
HANDRAILS AND STEPS...9693
MOUNTING AND DISMOUNTING...9694
NO PERSONS ON ATTACHMENTS...9694
BURN PREVENTION...9694
FIRE PREVENTION AND EXPLOSION PREVENTION...9695
ACTION IF FIRE OCCURS...9696
WINDSHIELD WASHER FLUID...9696
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...9696
ATTACHMENT INSTALLATION...9696
ATTACHMENT COMBINATIONS...9697
CAB WIDOW GLASSES...9697
UNAUTHORIZED MODIFICATIONS...9697
SAFETY AT JOBSITE...9697
WORKING ON LOOSE GROUND...9698
DISTANCE TO HIGH VOLTAGE CABLES...9698
ENSURE GOOD VISIBILITY...9698
VENTILATION FOR ENCLOSED AREA...9699
SIGNALMAN'S SIGNAL AND SIGNS...9699
EMERGENCY EXIT FROM OPERATOR'S CAB...9699
ASBESTOS DUST HAZARD PREVENTION...9699
SAFETY MACHINE OPERATION...9700
STARTING ENGINE...9700
CHECKS BEFORE STARTING ENGINE...9700
SAFETY RULES FOR STARTING ENGINE...9701
STARTING ENGINE IN COLD WEATHER...9701
OPERATION...9702
CHECKS AFTER STARTING ENGINE...9702
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...9702
SAFETY RULES FOR TRAVELING...9703
TRAVELING ON SLOPES...9704
OPERATIONS ON SLOPES...9705
PROHIBITED OPERATIONS...9705
OPERATIONS ON SNOW...9707
PARKING MACHINE...9707
TRANSPORTATION...9708
SHIPPING THE MACHINE...9708
BATTERY...9709
BATTERY HAZARD PREVENTION...9709
STARTING ENGINE WITH BOOSTER CABLES...9710
TOWING...9711
SAFETY RULES FOR TOWING...9711
LIFTING OBJECTS WITH BUCKET...9712
SAFETY RULES FOR LIFTING OBJECTS...9712
SAFETY MAINTENANCE INFORMATION...9713
WARNING TAG...9713
KEEP WORK PLACE CLEAN AND TIDY...9713
APPOINT LEADER WHEN WORKING WITH OTHERS...9713
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...9714
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...9715
PROPER TOOLS...9715
ACCUMULATOR...9716
PERSONNEL...9716
ATTACHMENTS...9716
WORK UNDER THE MACHINE...9716
NOISE...9717
WHEN USING HAMMER...9717
WELDING WORKS...9717
REMOVING BATTERY TERMINALS...9717
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...9718
DO NOT DISASSEMBLE RECOIL SPRINGS...9718
SAFETY RULES FOR HIGH-PRESSURE OIL...9718
SAFETY HANDLING HIGH-PRESSURE HOSES...9719
WASTE MATERIALS...9719
AIR CONDITIONER MAINTENANCE...9719
COMPRESSED AIR...9719
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...9720
OPERATION...9721
GENERAL VIEW...9722
GENERAL VIEW OF MACHINE...9722
GENERAL VIEW CONTROLS AND GAUGES...9723
EXPLANATION OF COMPONENTS...9724
MACHINE MONITOR...9724
BASIC CHECK ITEMS...9725
SWITCHES...9737
CONTROL LEVERS, PEDALS...9743
CEILING WINDOW...9746
FRONT WINDOW...9747
EMERGENCY EXIT FROM OPERATOR'S CAB...9752
DOOR LOCK...9752
CAP, COVER WITH LOCK...9753
HOT AND COOL BOX...9754
MAGAZINE BOX...9754
ASHTRAY...9754
AIR CONDITIONER CONTROLS...9755
CAR RADIO...9769
FUSE...9775
FUSIBLELINK...9776
CONTROLLER (COMPUTER)...9777
TOOLBOX...9777
GREASE GUN HOLDER...9777
HANDLING ACCUMULATOR...9778
MACHINE OPERATIONS AND CONTROLS...9779
BEFORE STARTING ENGINE...9779
STARTING ENGINE...9793
AFTER STARTING ENGINE...9797
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)...9799
STOPPING THE ENGINE...9802
CHECK AFTER SHUT OFF ENGINE...9802
MACHINE OPERATION...9803
STEERING THE MACHINE...9807
SWINGING...9809
WORK EQUIPMENT CONTROLS AND OPERATIONS...9810
OPERATING WORKING MODE...9812
PROHIBITED OPERATIONS...9813
GENERAL OPERATION INFORMATION...9815
TRAVELING ON SLOPES...9816
ESCAPE FROM MUD...9818
RECOMMENDED APPLICATIONS...9819
REPLACEMENT AND INVERSION OF BUCKET...9821
PARKING MACHINE...9825
CHECK AFTER FINISHING WORK...9826
LOCKING...9827
TRANSPORTATION...9828
TRANSPORTATION PROCEDURE...9828
LOADING AND UNLOADING WITH TRAILER...9829
LIFTING MACHINE...9837
COLD WEATHER OPERATION...9839
COLD WEATHER OPERATION INFORMATION...9839
AFTER DAILY WORK COMPLETION...9841
AFTER COLD WEATHER SEASON...9841
LONG TERM STORAGE...9842
BEFORE STORAGE...9842
DURING STORAGE...9842
AFTER STORAGE...9843
TROUBLESHOOTING...9844
AFTER RUNNING OUT OF FUEL...9844
PHENOMENA THAT ARE NOT FAILURES...9844
TOWING THE MACHINE...9845
LIGHTWEIGHT TOWING HOLE...9846
SEVERE JOB CONDITION...9846
DISCHARGED BATTERY...9847
OTHER TROUBLE...9851
MAINTENANCE...9856
MAINTENANCE INFORMATION...9857
OUTLINE OF SERVICE...9860
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...9860
ELECTRIC SYSTEM MAINTENANCE...9864
HANDLING HYDRAULIC SYSTEM...9864
WEAR PARTS LIST...9866
RECOMMENDED FUEL, COOLANT AND LUBRICANTS...9867
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...9868
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...9869
TIGHTENING TORQUE SPECIFICATIONS...9870
TIGHTENING TORQUE LIST...9870
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...9871
SAFETY CRITICAL PARTS...9872
MAINTENANCE SCHEDULE...9873
MAINTENANCE SCHEDULE CHART...9873
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...9876
MAINTENANCE PROCEDURE...9877
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...9877
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)...9877
WHEN REQUIRED...9878
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...9878
CLEAN INSIDE OF COOLING SYSTEM...9883
CHECK AND TIGHTEN TRACK SHOE BOLTS...9886
CHECK AND ADJUST TRACK TENSION...9887
CHECK ELECTRICAL INTAKE AIR HEATER...9889
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...9890
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...9893
REPLACE BUCKET SIDE CUTTER, SHROUD...9894
ADJUST BUCKET CLEARANCE...9895
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...9896
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)...9897
WASHING WASHABLE FLOOR...9898
METHOD OF SETTING MACHINE ANGLE...9900
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...9903
CHECK BEFORE STARTING...9904
EVERY 50 HOURS MAINTENANCE...9905
LUBRICATING...9905
EVERY 100 HOURS MAINTENANCE...9906
LUBRICATING...9906
EVERY 250 HOURS MAINTENANCE...9908
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...9908
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...9909
CHECK LEVEL OF BATTERY ELECTROLYTE...9910
LUBRICATE SWING CIRCLE (2 PLACES)...9912
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...9913
EVERY 500 HOURS MAINTENANCE...9914
REPLACE FUEL FILTER CARTRIDGE...9914
CHECK SWING PINION GREASE LEVEL, ADD GREASE...9915
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...9916
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS...9918
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...9919
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...9921
EVERY 1000 HOURS MAINTENANCE...9922
REPLACE HYDRAULIC FILTER ELEMENT...9922
CHANGE OIL IN SWING MACHINERY CASE...9924
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...9925
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...9925
CHECK PLAY OF TURBOCHARGER ROTOR...9925
REPLACE CORROSION RESISTOR CARTRIDGE...9925
CHECK FAN BELT TENSION AND REPLACE FAN BELT...9926
EVERY 2000 HOURS MAINTENANCE...9927
CHANGE OIL IN FINAL DRIVE CASE...9927
CLEAN HYDRAULIC TANK STRAINER...9928
CLEAN ENGINE BREATHER...9928
CLEAN, CHECK TURBOCHARGER...9929
CHECK ALTERNATOR, STARTING MOTOR...9929
CHECK ENGINE VALVE CLEARANCE, ADJUST...9929
CHECK VIBRATION DAMPER...9929
EVERY 4000 HOURS MAINTENENCE...9930
CHECK WATER PUMP...9930
EVERY 5000 HOURS MAINTENANCE...9931
CHANGE OIL IN HYDRAULIC TANK...9931
SPECIFICATIONS...9932
SPECIFICATIONS...9933
ATTACHMENTS AND OPTIONS...9935
GENERAL PRECAUTIONS...9936
PRECAUTIONS RELATED TO SAFETY...9936
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...9938
HANDLING BUCKET WITH HOOK...9939
CHECKING FOR DAMAGE TO BUCKET WITH HOOK...9939
PROHIBITED OPERATIONS...9939
MACHINES READY FOR ATTACHMENTS...9940
EXPLANATION OF COMPONENTS...9940
HYDRAULIC CIRCUIT...9943
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...9947
OPERATION...9949
LONG-TERM STORAGE...9951
SPECIFICATIONS...9951
HANDLING SCSH BUSHING...9952
EVERY 250 HOURS MAINTENANCE...9952
EVERY 500 HOURS MAINTENANCE...9953
ATTACHMENT GUIDE...9955
COMBINATIONS OF WORK EQUIPMENT...9955
SELECTING TRACK SHOE...9957
RECOMMENDED ATTACHMENT OPERATIONS...9958
HYDRAULIC BREAKER...9958
MULTI-MONITOR SPECIFICATION...9963
CONTENTS...9964
OPERATION...0
GENERAL VIEW...9965
GENERAL VIEW CONTROLS AND GAUGES...9965
EXPLANATION OF COMPONENTS...9966
MACHINE MONITOR...9966
BASIC CHECK ITEMS...9969
MACHINE OPERATIONS AND CONTROLS...9990
BEFORE STARTING ENGINE...9990
STARTING ENGINE...9993
AFTER STARTING ENGINE...9997
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)...10001
MACHINE OPERATION...10005
SWINGING...10008
OPERATING WORKING MODE...10009
GENERAL OPERATION INFORMATION...10010
CHECK AFTER FINISHING WORK...10011
TRANSPORTATION...10012
TRANSPORTATION PROCEDURE...10012
LOADING AND UNLOADING WITH TRAILER...10013
COLD WEATHER OPERATION...10021
MONITOR...10021
MAINTENANCE...0
MAINTENANCE PROCEDURE...10022
WHEN REQUIRED...10022
INDEX...10027
TEN00182-03 - Hydraulic Excavator PC300-8, PC300LC-8, PC350-8, PC350LC-8 Shop Manual...10030
COVER...10030
FOREWORD...10031
BEFORE READING THIS MANUAL...10032
SAFETY INFORMATION...10033
INTRODUCTION...10034
USE OF MACHINE...10034
DIRECTIONS OF MACHINE...10034
VISIBILITY FROM OPERATOR'S SEAT...10034
PRODUCT INFORMATION...10035
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...10035
EPA REGULATIONS, ENGINE NUMBER PLATE...10035
SERVICE METER LOCATION...10036
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...10036
CONTENTS...10037
SAFETY...10041
SAFETY...10042
SAFETY LABELS...10045
LOCATION OF SAFETY LABELS...10045
SAFETY LABELS...10046
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...10052
PRECAUTIONS BEFORE STARTING OPERATION...10052
PREPARATIONS FOR SAFE OPERATION...10052
FIRE PREVENTION...10054
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...10055
DO NOT GET CAUGHT IN WORK EQUIPMENT...10057
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...10057
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS...10057
UNAUTHORIZED MODIFICATION...10058
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...10058
PRECAUTIONS RELATED TO CAB GLASS...10058
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...10058
PRECAUTIONS FOR OPERATION...10059
PRECAUTIONS FOR JOBSITE...10059
STARTING ENGINE...10061
OPERATION...10063
TRANSPORTATION...10071
TOWING...10072
LIFTING OBJECTS WITH BUCKET...10073
PRECAUTIONS FOR MAINTENANCE...10074
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...10074
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...10078
OPERATION...10085
MACHINE VIEW ILLUSTRATIONS...10086
OVERALL MACHINE VIEW...10086
CONTROLS AND GAUGES...10087
DETAILED CONTROLS AND GAUGES...10089
MONITORING SYSTEM...10089
SWITCHES...10155
CONTROL LEVERS AND PEDALS...10160
SUN ROOF...10163
WINDSHIELD...10163
EMERGENCY ESCAPE HAMMER...10169
DOOR LOCK...10169
CAP WITH LOCK...10170
DRINK BOX...10172
MAGAZINE BOX...10172
ASHTRAY...10172
AIR CONDITIONER CONTROLS...10173
RADIO...10186
AUXILIARY ELECTRIC POWER...10191
FUSE...10192
FUSIBLE LINK...10193
CONTROLLER...10193
TOOL BOX...10194
GREASE PUMP HOLDER...10194
FIRE EXTINGUISHER...10194
MACHINE OPERATIONS AND CONTROLS...10195
BEFORE STARTING ENGINE...10195
STARTING ENGINE...10215
AFTER STARTING ENGINE...10218
STOPPING THE ENGINE...10229
MACHINE OPERATION...10230
STEERING THE MACHINE...10234
SWINGING...10236
WORK EQUIPMENT CONTROLS AND OPERATIONS...10237
WORKING MODE...10239
PROHIBITED OPERATIONS...10241
GENERAL OPERATION INFORMATION...10246
TRAVELING ON SLOPES...10248
ESCAPE FROM MUD...10250
RECOMMENDED APPLICATIONS...10251
BUCKET REPLACEMENT AND INVERSION...10253
PARKING MACHINE...10257
MACHINE INSPECTION AFTER DAILY WORK...10258
LOCKING...10259
TRANSPORTATION...10260
TRANSPORTATION PROCEDURE...10260
LOADING AND UNLOADING WITH TRAILER...10261
LIFTING MACHINE...10270
TRANSPORTATION POSTURE...10272
COLD WEATHER OPERATION...10274
COLD WEATHER OPERATION INFORMATION...10274
AFTER DAILY WORK COMPLETION...10276
AFTER COLD WEATHER SEASON...10276
LONG TERM STORAGE...10277
BEFORE STORAGE...10277
DURING STORAGE...10277
AFTER STORAGE...10278
STARTING MACHINE AFTER LONG-TERM STORAGE...10278
TROUBLES AND ACTIONS...10279
RUNNING OUT OF FUEL...10279
PHENOMENA THAT ARE NOT FAILURES...10280
TOWING THE MACHINE...10281
LIGHTWEIGHT TOWING HOLE...10282
SEVERE JOB CONDITION...10282
DISCHARGED BATTERY...10283
OTHER TROUBLE...10287
MAINTENANCE...10293
MAINTENANCE INFORMATION...10294
OUTLINE OF SERVICE...10296
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...10296
ELECTRIC SYSTEM MAINTENANCE...10299
WEAR PARTS...10300
WEAR PARTS LIST...10300
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...10301
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...10303
TIGHTENING TORQUE SPECIFICATIONS...10304
TIGHTENING TORQUE LIST...10304
SAFETY CRITICAL PARTS...10305
SAFETY CRITICAL PARTS LIST...10306
MAINTENANCE SCHEDULE...10307
MAINTENANCE SCHEDULE CHART...10307
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...10309
MAINTENANCE PROCEDURE...10310
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)...10310
WHEN REQUIRED...10311
CHECK BEFORE STARTING...10339
EVERY 50 HOURS MAINTENANCE...10340
EVERY 250 HOURS MAINTENANCE...10341
EVERY 500 HOURS MAINTENANCE...10344
EVERY 1000 HOURS MAINTENANCE...10359
EVERY 2000 HOURS MAINTENANCE...10365
EVERY 4000 HOURS MAINTENANCE...10372
EVERY 5000 HOURS MAINTENANCE...10375
EVERY 8000 HOURS MAINTENANCE...10377
SPECIFICATIONS...10379
SPECIFICATIONS...10380
ATTACHMENTS, OPTIONS...10383
GENERAL PRECAUTIONS FOR SAFETY...10384
PRECAUTIONS WHEN SELECTING...10384
READ THE INSTRUCTION MANUAL THOROUGHLY...10384
PRECAUTIONS WHEN REMOVING OR INSTALLING...10384
PRECAUTIONS WHEN USING...10384
BUCKET WITH HOOK...10385
HOOK CONDITION...10385
PROHIBITED OPERATIONS...10385
MACHINE READY FOR ATTACHMENT...10386
LOCATIONS...10386
HYDRAULIC CIRCUIT...10390
ATTACHMENT REMOVAL AND INSTALLATION...10395
ATTACHMENT OPERATIONS...10399
LONG TERM STORAGE...10400
SPECIFICATIONS...10400
ATTACHMENT GUIDE...10401
ATTACHMENT COMBINATIONS...10402
TRACK SHOES SELECTION...10403
RECOMMENDED ATTACHMENT OPERATIONS...10404
HYDRAULIC BREAKER...10404
HANDLING MACHINES EQUIPPED WITH KOMTRAX...10408
BASIC PRECAUTIONS...10408
INDEX...10409
UEN01983-03 - Hydraulic Excavator PC350LC-8, PC350LCD-8, PC350NLC-8, PC350NLCD-8 Shop Manual...10413
00 Index and foreword...10415
Index...10415
Composition of shop manual...10416
Table of contents...10418
00 Index and foreword...10427
Foreword and general information...10427
Safety notice...10428
How to read the shop manual...10433
Explanation of terms for maintenance standard...10435
Handling electric equipment and hydraulic component...10437
How to read electric wire code...10449
Precautions when carrying out operation...10452
Method of disassembling and connecting push-pull type coupler...10455
Standard tightening torque table...10458
Conversion table...10462
01 Specification...10469
Specification and technical data...10469
Specification dimension drawings...10470
Specifications...10472
Weight table...10475
Table of fuel, coolant and lubricants...10476
10 Structure, function and maintenance standard...10479
Engine and cooling system...10479
Engine and cooling system...10480
Engine related parts...10480
Radiator, oil cooler and aftercooler...10481
Diesel Particulate Filter...10482
Diesel Particulate Filter - Component Parts...10483
System Description...10484
Regeneration...10484
10 Structure, function and maintenance standard...10487
Power train...10487
Power train...10488
Final drive...10490
Sprocket...10492
Swing machinery...10494
Swing circle...10496
10 Structure, function and maintenance standard...10499
Undercarriage and frame...10499
Track frame and recoil spring...10500
Idler...10502
Carrier roller...10504
Track roller...10505
Track shoe...10506
10 Structure, function and maintenance standard...10511
Hydraulic system, Part 1...10511
Hydraulic equipment layout drawing...10512
Hydraulic tank and filter...10514
Hydraulic pump...10516
10 Structure, function and maintenance standard...10541
Hydraulic system, Part 2...10541
Control valve...10542
CLSS...10554
Functions and operation by valve...10558
Merge-divider valve...10573
Attachment circuit selector valve...10598
Hydraulic drift prevention valve...10600
10 Structure, function and maintenance standard...10607
Hydraulic system, Part 3...10607
Valve control...10608
PPC valve...10610
Solenoid valve...10632
PPC accumulator...10634
Return oil filter...10635
Centre swivel joint...10636
Travel motor...10637
Swing motor...10649
Hydraulic cylinder...10658
10 Structure, function and maintenance standard...10661
Work equipment...10661
Work equipment...10662
Work equipment...10662
Dimensions of components...10664
10 Structure, function and maintenance standard...10669
Cab and its attachments...10669
Air conditioner piping...10670
10 Structure, function and maintenance standard...10673
Electrical system...10673
Engine control...10674
Electronic control system...10683
Monitor system...10709
Sensor...10736
KOMTRAX terminal system...10739
10 Structure, function and maintenance standard...10743
Auto Grease system...10743
Outline of Auto Grease System...10744
20 Standard value table...10759
Standard service value table...10759
Standard value table for engine related parts...10760
Standard value table for chassis related parts...10761
30 Testing and adjusting...10773
Testing and adjusting, Part 1...10773
Tools for testing, adjusting and troubleshooting...10775
Measuring engine speed...10779
Measuring air boost pressure...10780
Measuring exhaust gas color...10781
Adjusting valve clearance...10783
Measuring compression pressure...10785
Measuring blow-by pressure...10789
Measuring engine oil pressure...10790
Measuring fuel pressure...10791
Handling during cylinder cut-out operation...10795
Handling during no injection cranking operation...10795
Measuring fuel return rate and leakage...10796
Bleeding air from fuel circuit...10798
Checking fuel circuit for leakage...10799
Testing and adjusting air compressor belt tension...10800
Measuring clearance in swing circle bearings...10801
Testing and adjusting track shoe tension...10802
Testing and adjusting oil pressure in work equipment, swing and travel circuit...10803
Testing and adjusting control circuit oil pressure...10807
Testing and adjusting pump PC control circuit oil pressure...10808
Testing and adjusting pump LS control circuit oil pressure...10811
Measuring solenoid valve output pressure...10816
Measuring PPC valve output pressure...10820
Adjusting play of work equipment and swing PPC valves...10821
Inspecting locations of hydraulic drift of work equipment...10822
Releasing remaining pressure in hydraulic circuit...10824
Measuring oil leakage amount...10824
Bleeding air from various parts...10827
Diode inspection procedures...10829
30 Testing and adjusting...10831
Testing and adjusting, Part 2...10831
Special functions of machine monitor...10832
30 Testing and adjusting...10889
Testing and adjusting, Part 3...10889
Handling voltage circuit of engine controller...10890
Preparation work for troubleshooting of electrical system...10891
Procedure for testing diodes...10895
Pm clinic service...10896
40 Troubleshooting...10903
Failure code table and fuse locations...10903
Failure codes table...10904
Fuse locations...10907
40 Troubleshooting...10913
General information on troubleshooting...10913
Points to remember when troubleshooting...10914
Sequence of events in troubleshooting...10915
Checks before troubleshooting...10916
Classification and troubleshooting steps...10917
Information in troubleshooting table...10918
Connection table for connector pin numbers...10923
T-adapter box and T-adapter table...10955
40 Troubleshooting...10961
Troubleshooting by failure code (Display of code), Part 1...10961
Failure code [A000N1] Eng. Hi Out of Std...10963
Failure code [AA10NX] Air cleaner Clogging...10964
Failure code [AB00KE] Charge Voltage Low...10966
Failure code [B@BAZG] Eng Oil Press. Low...10968
Failure code [B@BAZK] Eng Oil Level Low...10970
Failure code [B@BCNS] Eng. Water Overheat...10972
Failure code [B@BCZK] Eng Water Level Low...10974
Failure code [B@HANS] Hydr Oil Overheat...10976
Failure code [CA111] EMC Critical Internal Failure...10977
Failure code [CA115] Eng Ne and Bkup Speed Sens Error...10977
Failure code [CA122] Chg Air Press Sensor High Error...10978
Failure code [CA123] Chg Air Press Sensor Low Error...10980
Failure code [CA131] Throttle Sensor High Error...10982
Failure code [CA132] Throttle Sensor Low Error...10984
Failure code [CA144] Coolant Temp Sens High Error...10986
Failure code [CA145] Coolant Temp Sens Low Error...10988
Failure code [CA153] Chg Air Temp Sensor High Error...10990
Failure code [CA154] Chg Air Temp Sensor Low Error...10992
Failure code [CA187] Sens Supply 2 Volt Low Error...10994
Failure code [CA221] Ambient Press Sens High Error...10996
Failure code [CA222] Ambient Press Sens Low Error...10998
Failure code [CA227] Sens Supply 2 Volt High Error...11000
Failure code [CA234] Eng Overspeed...11001
Failure code [CA238] Ne Speed Sens Supply Volt Error...11002
Failure code [CA271] IMV/PCV1 Short Error...11003
Failure code [CA272] IMV/PCV1 Open Error...11004
Failure code [CA322] Inj #1 Open/Short Error...11006
Failure code [CA323] Inj #5 Open/Short Error...11008
Failure code [CA324] Inj #3 Open/Short Error...11010
Failure code [CA325] Inj #6 Open/Short Error...11012
Failure code [CA331] Inj #2 Open/Short Error...11014
Failure code [CA332] Inj #4 Open/Short Error...11016
40 Troubleshooting...11019
Troubleshooting by failure code (Display of code), Part 2...11019
Failure code [CA342] Calibration Code Incompatibility...11021
Failure code [CA351] Injectors Drive Circuit Error...11022
Failure code [CA352] Sens Supply 1 Volt Low Error...11024
Failure code [CA386] Sens Supply 1 Volt High Error...11026
Failure code [CA428] Water in Fuel Sensor High Error...11028
Failure code [CA429] Water in Fuel Sensor Low Error...11030
Failure code [CA441] Battery Voltage Low Error...11032
Failure code [CA442] Battery Voltage High Error...11034
Failure code [CA449] Rail Press Very High Error...11036
Failure code [CA451] Rail Press Sensor High Error...11040
Failure code [CA452] Rail Press Sensor Low Error...11042
Failure code [CA553] Rail Press High Error...11044
Failure code [CA559] Rail Press Low Error...11045
Failure code [CA689] Eng Ne Speed Sensor Error...11047
Failure code [CA731] Eng Bkup Speed Sens Phase Error...11049
Failure code [CA757] All Persistent Data Lost Error...11050
Failure code [CA778] Eng Bkup Speed Sensor Error...11052
Failure code [CA1633] KOMNET Datalink Timeout Error...11054
Failure code [CA2185] Throt Sens Sup Volt High Error...11056
Failure code [CA2186] Throt Sens Sup Volt Low Error...11057
Failure code [CA2249] Rail Press Very Low Error...11058
Failure code [CA2265] Electric Lift Pump High Error...11060
Failure code [CA2266] Electric Lift Pump Low Error...11062
Failure code [CA2555] Grid Htr Relay Volt High Error...11064
Failure code [CA2556] Grid Htr Relay Volt Low Error...11066
Failure code [D110KB] Battery Relay Drive S/C...11068
Failure code [DA25KP] 5V sensor 1 power abnormality...11070
Failure code [DA2RMC] Pump Comm. Abnormality...11074
Failure code [DA2SKQ] Model Selection Abnormality...11076
40 Troubleshooting...11079
Troubleshooting by failure code (Display of code), Part 3...11079
Failure code [DAFRMC] CAN discon (Monitor detected)...11082
Failure code [DHPAMA] F Pump Press Sensor Abnormality...11084
Failure code [DHPBMA] R Pump Press Sensor Abnormality...11086
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality...11088
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality...11090
Failure code [DW43KA] Travel Speed Sol. Disc...11092
Failure code [DW43KB] Travel Speed Sol. S/C...11094
Failure code [DW45KA] Swing Brake Sol. Disc...11096
Failure code [DW45KB] Swing Brake Sol. S/C...11100
Failure code [DW91KA] Travel Junction Sol. Disc...11102
Failure code [DW91KB] Travel Junction Sol. S/C...11104
Failure code [DWJ0KA] Merge-divider Sol. Disc...11106
Failure code [DWJ0KB] Merge-divider Sol. S/C...11108
Failure code [DWK0KA] 2-stage Relief Sol. Disc...11110
Failure code [DWK0KB] 2-stage Relief Sol. S/C...11112
Failure code [DXA0KA] PC-EPC Sol. Disc...11114
Failure code [DXA0KB] PC-EPC Sol. S/C...11116
Failure code [DXE0KA] LS-EPC Sol. Disc...11118
Failure code [DXE0KB] LS-EPC Sol. S/C...11120
Failure code [DXE4KA] Service Current EPC Disc...11122
Failure code [DXE4KB] Service Current EPC S/C...11123
Failure code [DY20KA] Wiper Working Abnormality...11124
Failure code [DY20MA] Wiper Parking Abnormality...11126
Failure code [DY2CKB] Washer Drive Short...11128
Failure code [DY2DKB] Wiper Drive (For) Short...11130
Failure code [DY2EKB] Wiper Drive (Rev) Short...11132
40 Troubleshooting...11135
Troubleshooting of electrical system (E-mode)...11135
Before carrying out troubleshooting of electrical system...11138
Information contained in troubleshooting table...11140
E-1 Engine does not start...11141
E-2 Auto-decelerator does not operate...11144
E-3 Automatic warming-up system does not operate...11146
E-4 Preheater does not operate...11148
E-5 All work equipment, swing, and travel mechanism do not move...11150
E-6 Power maximizing function does not operate...11152
E-7 Machine monitor does not display at all...11154
E-8 Machine monitor does not display some items...11156
E-9 Contents of display by machine monitor are different from applicable machine...11156
E-10 Fuel level monitor was lighted in red while engine running...11157
E-11 Engine coolant temperature gauge does not indicate normally...11158
E-12 Hydraulic oil temperature gauge does not indicate normally...11160
E-13 Fuel level gauge does not indicate normally...11161
E-14 Swing lock monitor does not indicate normally...11162
E-15 When monitor switch is operated, monitor displays nothing...11164
E-16 Windshield wiper and window washer do not operate...11166
E-17 Machine push-up function does not operate normally...11170
E-18 Monitoring function fails to display “boom raise” normally...11172
E-19 Monitoring function fails to display “boom lower” normally...11174
E-20 Monitoring function fails to display “arm IN” normally...11176
E-21 Monitoring function fails to display “arm OUT” normally...11178
E-22 Monitoring function fails to display “bucket CURL” normally...11180
E-23 Monitoring function fails to display “bucket DUMP” normally...11182
E-24 Monitoring function fails to display “swing” normally...11184
E-25 Monitoring function fails to display “travel” normally...11186
E-26 Monitoring function fails to display “travel differential pressure” normally...11188
E-27 Monitoring function fails to display “service” normally...11190
E-28 KOMTRAX system does not operate normally...11192
E-29 Air conditioner does not operate...11194
E-30 Travel alarm does not sound or does not stop sounding...11196
E-31 Horn does not sound...11198
40 Troubleshooting...11201
Troubleshooting of hydraulic and mechanical system (H-mode)...11201
System chart for hydraulic and mechanical system...11204
Information contained in troubleshooting table...11206
H-1 All work equipment lack power, or travel and swing speeds are slow...11208
H-2 Engine speed sharply drops or engine stalls...11210
H-3 No work equipment, swing or travel move...11211
H-4 Abnormal noise is heard from around hydraulic pump...11211
H-5 Auto-decelerator does not work...11212
H-6 Fine control mode does not function or responds slow...11212
H-7 Boom moves slowly or lacks power...11213
H-8 Arm moves slowly or lacks power...11214
H-9 Bucket moves slowly or lacks power...11215
H-10 Work equipment does not move in its single operation...11215
H-11 Work equipment has a bit too fast hydraulic drift...11216
H-12 Work equipment has big time lag...11218
H-13 Other work equipment moves when relieving single circuit...11218
H-14 Power max. switch does not operate...11219
H-15 In compound operation, work equipment with larger load moves slowly...11219
H-16 In swing + boom RAISE operation, boom moves slowly...11220
H-17 In swing + travel operation, travel speed drops sharply...11220
H-18 Machine swerves in travel...11221
H-19 Machine travels slowly...11222
H-20 Machine cannot be easily steered or lacks power...11223
H-21 Travel speed does not shift, or it is too slow or fast...11224
H-22 Track shoe does not turn (on one side only)...11225
H-23 Machine does not swing...11226
H-24 Swing acceleration is poor, or swing speed is slow...11228
H-25 Excessive overrun when stopping swing...11230
H-26 There is big shock when stopping swing...11231
H-27 Large sound is made when upper structure stops swinging...11231
H-28 Swing hydraulic drift is too big...11232
40 Troubleshooting...11235
Troubleshooting of engine (S-mode)...11235
Method of using troubleshooting chart...11237
S-1 Starting performance is poor...11240
S-2 Engine does not start...11241
S-3 Engine does not pick up smoothly...11244
S-4 Engine stops during operations...11245
S-5 Engine does not rotate smoothly...11246
S-6 Engine lacks output (or lacks power)...11247
S-7 Exhaust smoke is black (incomplete combustion)...11248
S-8 Oil consumption is excessive (or exhaust smoke is blue)...11249
S-9 Oil becomes contaminated quickly...11250
S-10 Fuel consumption is excessive...11251
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...11252
S-12 Oil pressure drops...11253
S-13 Oil level rises (Entry of coolant or fuel)...11254
S-14 Coolant temperature becomes too high (overheating)...11255
S-15 Abnormal noise is made...11256
S-16 Vibration is excessive...11257
S-17 Diesel Particulate Filter System...11258
40 Troubleshooting...11261
Troubleshooting of Auto Grease system...11261
50 Disassembly and assembly...11269
General information on disassembly and assembly...11269
How to read this manual...11270
Coating materials list...11272
Special tools list...11275
Sketches of special tools...11279
50 Disassembly and assembly...11283
Engine and cooling system...11283
Removal and installation of fuel supply pump assembly...11284
Removal and installation of engine front seal...11287
Removal and installation of engine rear seal...11289
Removal and installation of cylinder head assembly...11294
Removal and installation of radiator assembly...11306
Removal and installation of hydraulic oil cooler assembly...11308
Removal and installation of aftercooler assembly...11310
Removal and installation of engine and hydraulic pump assembly...11311
50 Disassembly and assembly...11317
Power train...11317
Removal and installation of final drive assembly...11318
Disassembly and assembly of final drive assembly...11319
Removal and installation of swing motor and swing machinery assembly...11327
Disassembly and assembly of swing motor and swing machinery assembly...11328
Removal and installation of swing circle assembly...11335
50 Disassembly and assembly...11337
Undercarriage and frame...11337
Disassembly and assembly of carrier roller...11338
Disassembly and assembly of track roller assembly...11339
Disassembly and assembly of idler assembly...11340
Disassembly and assembly of recoil spring...11343
Removal and installation of sprocket...11345
Expansion and installation of track shoe assembly...11346
Removal and installation of revolving frame assembly...11347
Removal and installation of counterweight assembly...11349
50 Disassembly and assembly...11351
Hydraulic system...11351
Removal and installation of centre swivel joint assembly...11352
Disassembly and assembly of centre swivel joint assembly...11354
Removal and installation of hydraulic tank assembly...11355
Removal and installation of control valve assembly...11357
Disassembly and assembly of control valve assembly...11360
Removal and installation of hydraulic pump assembly...11362
Removal and installation of oil seal in hydraulic pump input shaft...11364
Disassembly and assembly of work equipment PPC valve assembly...11365
Disassembly and assembly of travel PPC valve assembly...11366
Disassembly and assembly of hydraulic cylinder assembly...11367
50 Disassembly and assembly...11373
Work equipment...11373
Removal and installation of work equipment assembly...11374
50 Disassembly and assembly...11379
Cab and its attachments...11379
Removal and installation of operator's cab assembly...11380
Removal and installation of operator cab glass (stuck glass)...11383
Removal and installation of front window assembly...11393
Removal and installation of floor frame assembly...11400
50 Disassembly and assembly...11405
Electrical system...11405
Removal and installation of air conditioner unit assembly...11406
Removal and installation of KOMTRAX communication modem assembly...11409
Removal and installation of monitor assembly...11410
Removal and installation of pump controller assembly...11412
Removal and installation of engine controller...11414
90 Diagrams and drawings...11417
Hydraulic diagrams and drawings...11417
90 Diagrams and drawings...11425
Electrical diagrams and drawings...11425
Komatsu Hydraulic Excavators PC300, PC300LC, PC350, PC350LC, PC350HD, PC350LCD, PC350NLC, PC350NLCD Series Repair Service Manuals
