Komatsu PC300LC-7L, PC300HD-7L Hydraulic Excavator Service Shop Manual (A85001 and up) - CEBM009104

This complete service repair workshop manual PDF download for the PC300LC-7L & PC300HD-7L Komatsu Hydraulic Excavator (SN: A85001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu PC300LC-7L - SN: A85001 and up
Komatsu PC300HD-7L - SN: A85001 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
20 TESTING, ADJUSTING AND TROUBLESHOOTING
30 DISASSEMBLY AND ASSEMBLY
90 OTHER


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM009104
Total Pages : 782


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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FOREWORD
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
GENERAL PRECAUTIONS
PREPARATIONS FOR WORK
PRECAUTIONS DURING WORK
GENERAL
HOW TO READ THE SHOP MANUAL
VOLUMES
DISTRIBUTION AND UPDATING
FILING METHOD
REVISED EDITION MARK
REVISIONS
SYMBOLS
HOISTING INSTRUCTIONS
HOISTING
WIRE ROPES
COATING MATERIALS
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
TIGHTENING TORQUE OF HOSE NUTS
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
TIGHTENING TORQUE FOR FLARED NUTS
ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE

01 GENERAL
SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
WORKING RANGES
DIMENSIONS
WORKING RANGES
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT, AND LUBRICANTS
PC300LC-7L
PC300HD-7L

10 STRUCTURE AND FUNCTION
ENGINE RELATED PARTS
RADIATOR • OIL COOLER • AFTERCOOLER
FINAL DRIVE
PC300LC-7L
PC300HD-7L
SPROCKET
REAL DIMENSION OF SPROCKET TOOTH SHAPE
SWING MACHINERY
SWING CIRCLE
TRACK FRAME • RECOIL SPRING
PC300LC-7L
PC300HD-7L
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
TRIPLE GROUSER SHOE
HYDRAULIC EQUIPMENT LAYOUT DRAWING
HYDRAULIC TANK
HYDRAULIC PUMP
HPV125 + 125
LS VALVE
PC VALVE
LS(PC)-EPC VALVE
VARIABLE VOLUME VALVE
CONTROL VALVE
MAIN RELIEF VALVE
VARIABLE PRESSURE COMPENSATION VALVE
CLSS
SELF PRESSURE REDUCING VALVE
SWING MOTOR
RELIEF VALVE PORTION
SWING LOCK
REVERSE PREVENTION VALVE
CENTER SWIVEL JOINT
TRAVEL MOTOR
PC300LC-7L
MOTOR OPERATION
PARKING BRAKE OPERATION
PC300HD-7L
MOTOR OPERATION
PARKING BRAKE OPERATION
BRAKE VALVE OPERATION
TRAVEL JUNCTION VALVE
TRAVEL PPC SHUTTLE VALVE
VALVE CONTROL
WORK EQUIPMENT • SWING PPC VALVE
TRAVEL PPC VALVE
SERVICE VALVE
SOLENOID VALVE
PPC ACCUMULATOR
RETURN OIL FILTER
FOR BREAKER
BOOM HYDRAULIC DRIFT PREVENTION VALVE
QUICK RETURN VALVE
LIFT CHECK VALVE
ATTACHMENT CIRCUIT SELECTOR VALVE
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
WORK EQUIPMENT
DIMENSION OF ARM
DIMENSION OF BUCKET
AIR CONDITIONER
PIPING
ENGINE CONTROL
FUEL CONTROL DIAL
GOVERNOR MOTOR
ENGINE THROTTLE AND PUMP CONTROLLER
INPUT AND OUTPUT SIGNALS
ELECTRONIC CONTROL SYSTEM
TOTAL SYSTEM DIAGRAM
MULTI MONITOR SYSTEM
MONITOR PANEL
MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION
MAINTENANCE FUNCTION
SENSORS
ENGINE OIL LEVEL SENSOR
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)
COOLANT TEMPERATURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
FUEL LEVEL SENSOR
AIR CLEANER CLOGGING SENSOR

20 TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLES
ENGINE RELATED
CHASSIS RELATED
TESTING AND ADJUSTING
SERVICE TOOLS
ENGINE
AIR BOOST PRESSURE
AIR COMPRESSOR BELT TENSION
BLOW-BY PRESSURE
COMPRESSION PRESSURE
ENGINE OIL PRESSURE
ENGINE RPM
ENGINE SPEED SENSOR
EXHAUST GAS COLOR
FUEL INJECTION TIMING
VALVE CLEARANCE
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE
SWING CIRCLE BEARINGS
TRACK SHOE TENSION
SPROCKET
OIL PRESSURE
WORK EQUIPMENT, SWING AND TRAVEL
CONTROL CIRCUIT
PUMP PC CONTROL CIRCUIT
PUMP LS CONTROL CIRCUIT
SOLENOID VALVE OUTPUT
PPC VALVE OUTPUT
WORK EQUIPMENT AND SWING PPC VALVE
WORK EQUIPMENT, HYDRAULIC DRIFT LOCATIONS
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT
BOOM AND BUCKET CYLINDERS
BOOM LOCK VALVE
ARM CYLINDER
PPC VALVE
OIL LEAKAGE AMOUNT
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
SWING MOTOR
TRAVEL MOTOR
AIR BLEEDING OF VARIOUS PARTS
DIODE INSPECTION PROCEDURES
MULTI-MONITOR PANEL
MONITOR PANEL FUNCTIONS
OPERATOR’S MENU AND DISPLAY (OUTLINE)
TABLE FOR SERVICE AND FAILURE CODE NOS.
SERVICE MENU
WAY OF SWITCHING TO SERVICE MENU
TABLE FOR MONITORING ITEMS
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARTIONS
PC300HD-7L Serial No. A85049 and UP
PC300LC-7L Serial No. A86675 and UP
PM TUNE SERVICE
TROUBLESHOOTING GENERAL
TROUBLESHOOTING POINTS TO REMEMBER
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CARRYING OUT MAINTENANCE POINTS TO REMEMBER
CHECKS BEFORE TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CONNECTOR TABLE
CONNECTOR LOCATION DIAGRAM
PC300HD-7L Serial No. A85049 and UP
PC300LC-7L Serial No. A86675 and UP
CONNECTOR LOCATION DIAGRAM
ELECTRICAL DIAGRAM FOLDOUTS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING ELECTRICAL SYSTEM (E-MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF
USER CODE MEMORY RETENTION FUNCTION
ERROR, FAILURE CODES AND POSSIBLE CAUSES
CONNECTION TABLE OF FUSE BOX
INFORMATION CONTAINED IN TESTING PROCEDURES
(E101) ABNORMAL DATA IN ERROR HISTORY
(E112) SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION
(E113) SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION
(E114) SHORT OR OPEN IN WINDOW WASHER SYSTEM
(E115) ABNORMAL WINDSHIELD WIPER MOTION
(E116) ABNORMALITY IN PARKING WIPER ARM
(E201) SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID
(E203) SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM
(E204) SHORT IN MERGE/DIVIDE SOLENOID
(E205) SHORT IN 2 STAGE RELIEF SOLENOID
(E206) SHORT IN TRAVEL SPEED SHIFT SOLENOID
(E211) OPEN IN TRAVEL INTERLOCKING SOLENOID
(E213) OPEN IN SWING PARKING BRAKE SOLENOID
(E214) OPEN OF MERGE/DIVIDE SOLENOID
(E215) OPEN IN 2 STAGE RELIEF SOLENOID
(E216) OPEN IN TRAVEL SPEED SOLENOID
(E217) ABNORMAL INPUT FOR MODEL CODE
(E218) OPEN IN S-NET SIGNAL
(E222) SHORT IN LS-EPC SOLENOID
(E223) OPEN IN LS-EPC SOLENOID SYSTEM
(E224) ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL
(E225) ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL
(E226) ABNORMAL PRESSURE SENSOR POWER SUPPLY
(E227) ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER
(E228) SHORT IN ATTACHMENT RETURN SWITCHING RELAY
(E232) SHORT IN PC-EPC SOLENOID
(E233) OPEN IN PC-EPC SOLENOID SYSTEM
(E238) OPEN IN ATTACHMENT RETURN SWITCH RELAY
(E245) SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM
(E246) OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM
(E256) INCORRECT NON-VOLATILE MEMORY DATA
(E304) SHORT IN ENGINE STOP SOLENOID SYSTEM
(E314) OPEN IN ENGINE STOP SOLENOID SYSTEM
(E306) ABNORMAL GOVERNOR POTENTIOMETER SIGNALS
(E308) ABNORMAL FUEL DIAL SIGNALS
(E315) SHORT IN BATTERY RELAY SYSTEM
(E316) STEP OUT IN GOVERNOR MOTOR
(E317) OPEN IN GOVERNOR MOTOR PHASE “A” AND “B”
(E318) SHORT IN GOVERNOR MOTOR PHASE “A” AND “B”
(E501) MODEL SELECTION FUNCTION NOT PROVIDED
(E502) MODEL SELECTING SIGNAL FAULT
(AA10NX) AIR CLEANER CLOG INDICATOR FAILURE
(AB00KE) LOW CHARGING VOLTAGE INDICATED
(B@BAZG) ABNORMAL ENGINE OIL PRESSURE
(B@BAZK) ABNORMAL ENGINE OIL LEVEL
(B@BCNS) ENGINE COOLANT INDICATING OVERHEAT CONDITION
(B@BCZK) ABNORMAL COOLANT LEVEL INDICATION
(B@HANS) HYDRAULIC OIL OVERHEAT INDICATION
TROUBLESHOOTING MONITOR ELECTRICAL SYSTEM (E-MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF
USER CODE MEMORY RETENTION FUNCTION
INFORMATION CONTAINED IN TESTING PROCEDURES
(E-1) ENGINE WILL NOT CRANK
(E-2) ENGINE STOPS WHILE IN OPERATION
(E-3) ENGINE SPEED IRREGULAR, OR HUNTING
(E-4) ENGINE DOES NOT SHUT DOWN
(E-5) AUTO DECELERATOR DOES NOT WORK
(E-6) AUTO ENGINE WARM UP DEVICE DOES NOT WORK
(E-7) COLD START PREHEATER DOES NOT WORK
(E-8) ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE
(E-9) ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE
(E-10) NO DISPLAY ON MONITOR PANEL
(E-11) PART OF DISPLAY ON MONITOR PANEL IS MISSING
(E-12) MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL
(E-13) FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL
(E-14) ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY
(E-15) HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY
(E-16) FUEL GAUGE DOES NOT DISPLAY CORRECTLY
(E-17) SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY
(E-18) WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS
(E-19) WINDSHIELD WIPER DOES NOT WORK
(E-20) ALARM BUZZER CANNOT BE CANCELLED
(E-21) BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR
(E-22) BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR
(E-23) ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR
(E-24) ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR
(E-25) BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR
(E-26) BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR
(E-27) SWING NOT CORRECTLY DISPLAYED ON MONITOR
(E-28) TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR
(E-29) TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR
(E-30) SERVICE NOT CORRECTLY DISPLAYED ON MONITOR
(E-31) AIR CONDITIONER SYSTEM DOES NOT WORK
(E-32) TRAVEL ALARM DOES NOT SOUND
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSEM (H-MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
(H-1) ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW
(H-2) ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS
(H-3) NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT
(H-4) ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP
(H-5) AUTO-DECELERATOR DOES NOT WORK
(H-6) FINE CONTROL MODE DOES NOT FUNCTION
(H-7) BOOM MOVES SLOWLY OR LACKS POWER
(H-8) ARM MOVES SLOWLY OR LACKS POWER
(H-9) BUCKET MOVES SLOWLY OR LACKS POWER
(H-10) WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION
(H-11) WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT
(H-12) WORK EQUIPMENT HAS EXCESSIVE LAG TIME
(H-13) OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT
(H-14) ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE
(H-15) IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY
(H-16) IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY
(H-17) IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY
(H-18) MACHINE SWERVES WHEN TRAVELING
(H-19) MACHINE TRAVELS SLOWLY
(H-20) MACHINE CANNOT BE STEERED EASILY OR LACKS POWER
(H-21) TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING.
(H-22) TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY)
(H-23) MACHINE DOES NOT SWING
(H-24) SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW
(H-25) EXCESSIVE OVERRUN WHEN STOPPING SWING
(H-26) THERE IS A SUDDEN SHOCK WHEN STOPPING SWING
(H-27) ABNORMAL NOISE CAUSED WHEN STOPPING SWING
(H-28) SWING NATURAL DRIFT IS EXCESSIVE

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS DURING OPERATION
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK
PRECAUTIONS WHEN COMPLETING THE OPERATIONS
OTHER PRECAUTIONS
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
ENGINE
ALTERNATOR
CYLINDER HEAD
ENGINE FRONT SEAL
ENGINE OIL COOLER
ENGINE REAR SEAL
FUEL INJECTION PUMP
NOZZLE HOLDER
STARTING MOTOR
THERMOSTAT
TURBOCHARGER
WATER PUMP
RADIATOR
REMOVAL
INSTALLATION
HYDRAULIC OIL COOLER
REMOVAL
INSTALLATION
ENGINE AND HYDRAULIC PUMPS
REMOVAL
INSTALLATION
FINAL DRIVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SWING MOTOR AND SWING MACHINERY
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CARRIER ROLLER
ASSEMBLY
TRACK ROLLER
ASSEMBLY
IDLER
DISASSEMBLY
ASSEMBLY
RECOIL SPRING
DISASSEMBLY
ASSEMBLY
SPROCKET
REMOVAL
INSTALLATION
TRACK SHOE
EXPANSION OF TRACK SHOE
ASSEMBLY
SWING CIRCLE
REMOVAL
INSTALLATION
REVOLVING FRAME
REMOVAL
INSTALLATION
CENTER SWIVEL JOINT
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
HYDRAULIC TANK
REMOVAL
INSTALLATION
CONTROL VALVE
REMOVAL
INSTALLATION
PROCEDURES FOR REPLACING PRESSURE COMPENSATION VALVE SEAL
ASSEMBLY
HYDRAULIC PUMP
REMOVAL
INSTALLATION
INPUT SHAFT OIL SEAL
REMOVAL
INSTALLATION
WORK EQUIPMENT PPC VALVE
ASSEMBLY
TRAVEL PPC VALVE
ASSEMBLY
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
AIR CONDITIONER
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL
INSTALLATION
OPERATOR’S CAB
REMOVAL
INSTALLATION
MONITOR
REMOVAL
INSTALLATION
GOVERNOR PUMP CONTROLLER
REMOVAL
INSTALLATION

90 OTHERS
ELECTRICAL
ELECTRICAL (PC300HD-7L SERIAL NO. A85001 THROUGH A85047 AND PC300LC-7L SERIAL NO. A85001 THROUGH A86673)
ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 3) FOLDOUT 1
ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 3) FOLDOUT 2
ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 3) FOLDOUT 3
ELECTRICAL DIAGRAM 2/4 (SHEET 1 OF 1) FOLDOUT 4
ELECTRICAL DIAGRAM 3/4 (SHEET 1 OF 2) FOLDOUT 5
ELECTRICAL DIAGRAM 3/4 (SHEET 2 OF 2) FOLDOUT 6
ELECTRICAL DIAGRAM 4/4 (SHEET 1 OF 2) FOLDOUT 7
ELECTRICAL DIAGRAM 4/4 (SHEET 2 OF 2) FOLDOUT 8
ELECTRICAL (PC300HD-7L SERIAL NO. A85049 AND UP/PC300LC-7L SERIAL NO. A86675 AND UP)
ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 9) FOLDOUT 1
ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 9) FOLDOUT 2
ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 9) FOLDOUT 3
ELECTRICAL DIAGRAM 2/4 (SHEET 4 OF 9) FOLDOUT 1
ELECTRICAL DIAGRAM 3/4 (SHEET 5 OF 9) FOLDOUT 2
ELECTRICAL DIAGRAM 3/4 (SHEET 6 OF 9) FOLDOUT 3
ELECTRICAL DIAGRAM 4/4 (SHEET 7 OF 9) FOLDOUT 1
ELECTRICAL DIAGRAM 4/4 (SHEET 8 OF 9) FOLDOUT 2
ELECTRICAL DIAGRAM 4/4 (SHEET 9 OF 9) FOLDOUT 3
HYDRAULIC
HYDRAULIC DIAGRAM (SHEET 1 OF 3) FOLDOUT 9
HYDRAULIC DIAGRAM (SHEET 2 OF 3) FOLDOUT 10
HYDRAULIC DIAGRAM (SHEET 3 OF 3) FOLDOUT 11

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