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Komatsu ecot3 PC300LC-8 manual available for free PDF download: Shop Manual
Komatsu ecot3 PC300LC-8 Shop Manual (1035 pages)
HYDRAULIC EXCAVATOR
Brand:
Komatsu
| Category:
Excavators
| Size: 53.69 MB
Table of Contents
Table of Contents
6
Safety Notice
16
How to Read the Shop Manual
21
Explanation of Terms for Maintenance Standard
23
Handling of Electric Equipment and Hydraulic Component
25
Handling of Connectors Newly Used for Engines
34
How to Read Electric Wire Code
37
Precautions When Carrying out Operation
40
Method of Disassembling and Connecting Push-Pull Type Coupler
43
Standard Tightening Torque Table
46
Conversion Table
50
Specification
57
Specification Dimension Drawings
58
Dimensions
58
Specifications
58
Working Ranges
59
Specifications
60
Weight Table
66
Table of Fuel, Coolant and Lubricants
68
Structure, Function and Maintenance Standard
71
Engine and Cooling System SEN01990-00
71
Engine Related Parts
72
Radiator, Oil Cooler and Aftercooler
73
Power Train
76
Structure, Function and Maintenance Standard
76
Swing Circle
77
Swing Machinery
78
Final Drive
80
Sprocket
82
Track Frame and Recoil Spring
86
Structure, Function and Maintenance Standard
86
Idler
88
Carrier Roller
90
Track Roller
91
Track Shoe
92
Hydraulic System, Part 1
97
Hydraulic Equipment Layout Drawing
98
Hydraulic Tank and Filter
100
Hydraulic Pump
102
Hydraulic System, Part 2
127
Control Valve
128
Structure, Function and Maintenance Standard
128
Clss
140
Functions and Operation by Valve
144
Merge-Divider Valve
159
Attachment Circuit Selector Valve
184
Hydraulic Drift Prevention Valve
186
Hydraulic System, Part 3
193
Valve Control
194
Structure, Function and Maintenance Standard
194
PPC Valve
196
Solenoid Valve
218
PPC Accumulator
220
Return Oil Filter
221
Center Swivel Joint
222
Travel Motor
223
Swing Motor
235
Hydraulic Cylinder
244
Work Equipment
248
Dimensions of Components
250
Air Conditioner Piping
256
Engine Control
260
Structure, Function and Maintenance Standard
260
Electronic Control System
269
Monitor System
294
Sensor
321
KOMTRAX System
324
Standard Value Table
327
Standard Value Table for Engine Related Parts
328
Standard Value Table for Chassis Related Parts
329
Testing and Adjusting
343
Tools for Testing, Adjusting and Troubleshooting
343
Sketches of Special Tools
347
Testing Engine Speed
348
Testing Air Boost Pressure
349
Testing Exhaust Gas Color
350
Adjusting Valve Clearance
352
Testing Compression Pressure
354
Testing Blow-By Pressure
358
Testing Engine Oil Pressure
359
Testing Fuel Pressure
360
Handling During Cylinder Cut-Out Operation
365
Handling During no Injection Cranking Operation
365
Testing Fuel Return Rate and Leakage
366
Bleeding Air from Fuel Circuit
368
Checking Fuel Circuit for Leakage
369
Testing and Adjusting Air Compressor Belt Tension
370
Replacing Fan Belt
371
Replacing Alternator Belt
372
Testing Clearance in Swing Circle Bearings
373
Testing and Adjusting Track Shoe Tension
374
Testing and Adjusting Oil Pressure in Work Equipment, Swing and Travel Circuit
375
Testing and Adjusting Control Circuit Oil Pressure
379
Testing and Adjusting Pump PC Control Circuit Oil Pressure
380
Testing and Adjusting Pump LS Control Circuit Oil Pressure
383
Testing Solenoid Valve Output Pressure
388
Testing PPC Valve Output Pressure
392
Adjusting Play of Work Equipment and Swing PPC Valves
393
Inspecting Locations of Hydraulic Drift of Work Equipment
394
Releasing Remaining Pressure in Hydraulic Circuit
396
Testing Oil Leakage Amount
396
Bleeding Air from Various Parts
399
Diode Inspection Procedures
401
Installation and Adjustment of Mirrors
402
Testing and Adjusting, Part 2
407
Special Functions of Machine Monitor
408
Testing and Adjusting, Part 3
465
Handling Voltage Circuit of Engine Controller
466
Testing and Adjusting
466
Preparation Work for Troubleshooting of Electrical System
467
Procedure for Testing Diodes
471
Pm Clinic Service
472
Troubleshooting
479
Failure Codes Table
480
Fuse Locations
483
Points to Remember When Troubleshooting
490
Troubleshooting
490
Sequence of Events in Troubleshooting
491
Checks before Troubleshooting
492
Classification and Troubleshooting Steps
493
Information in Troubleshooting Table
494
Possible Problems and Troubleshooting no
496
Connection Table for Connector Pin Numbers
499
T- Branch Box and T- Branch Adapter Table
535
Troubleshooting by Failure Code (Display of Code), Part
539
Failure Code [989L00] Engine Controller Lock Caution 1
541
Failure Code [989M00] Engine Controller Lock Caution 2
541
Failure Code [989N00] Engine Controller Lock Caution 3
542
Failure Code [AA10NX] Air Cleaner Clogging
544
Failure Code [AB00KE] Charge Voltage Low
546
Failure Code [B@BAZG] Eng Oil Press. Low
548
Failure Code [B@BAZK] Eng Oil Level Low
550
Failure Code [B@BCNS] Eng. Water Overheat
552
Failure Code [B@BCZK] Eng Water Level Low
554
Failure Code [B@HANS] Hydr Oil Overheat
556
Failure Code [CA111] EMC Critical Internal Failure
557
Failure Code [CA115] Eng Ne and Bkup Speed Sens Error
557
Failure Code [CA122] Chg Air Press Sensor High Error
558
Failure Code [CA123] Chg Air Press Sensor Low Error
560
Failure Code [CA131] Throttle Sensor High Error
562
Failure Code [CA132] Throttle Sensor Low Error
564
Failure Code [CA144] Coolant Temp Sens High Error
566
Failure Code [CA145] Coolant Temp Sens Low Error
568
Failure Code [CA153] Chg Air Temp Sensor High Error
570
Failure Code [CA154] Chg Air Temp Sensor Low Error
572
Failure Code [CA155] Chg Air Temp High Speed Derate
574
Failure Code [CA187] Sens Supply 2 Volt Low Error
576
Failure Code [CA221] Ambient Press Sens High Error
578
Failure Code [CA222] Ambient Press Sens Low Error
580
Failure Code [CA227] Sens Supply 2 Volt High Error
582
Failure Code [CA234] Eng Overspeed
583
Failure Code [CA238] Ne Speed Sens Supply Volt Error
584
Failure Code [CA271] IMV/PCV1 Short Error
585
Failure Code [CA272] IMV/PCV1 Open Error
586
Failure Code [CA281] Pump Press Balance Error
588
Failure Code [CA322] Inj #1 (L/B#1) Open/Short Error
589
Failure Code [CA323] Inj #5 (L/B#5) Open/Short Error
591
Failure Code [CA324] Inj #3 (L/B#3) Open/Short Error
593
Failure Code [CA325] Inj #6 (L/B#6) Open/Short Error
595
Failure Code [CA331] Inj #2 (L/B#2) Open/Short Error
597
Failure Code [CA332] Inj #4 (L/B#4) Open/Short Error
599
Troubleshooting by Failure Code (Display of Code), Part
603
Failure Code [CA342] Calibration Code Incompatibility
605
Troubleshooting
605
Failure Code [CA351] Injectors Drive Circuit Error
606
Failure Code [CA352] Sens Supply 1 Volt Low Error
608
Failure Code [CA386] Sens Supply 1 Volt High Error
610
Failure Code [CA428] Water in Fuel Sensor High Error
612
Failure Code [CA429] Water in Fuel Sensor Low Error
614
Failure Code [CA435] Eng Oil Press Sw Error
616
Failure Code [CA441] Battery Voltage Low Error
618
Failure Code [CA442] Battery Voltage High Error
620
Failure Code [CA449] Rail Press very High Error
622
Failure Code [CA451] Rail Press Sensor High Error
626
Failure Code [CA452] Rail Press Sensor Low Error
628
Failure Code [CA488] Chg Air Temp High Torque Derate
630
Failure Code [CA553] Rail Press High Error
630
Failure Code [CA559] Rail Press Low Error
632
Failure Code [CA689] Eng Ne Speed Sensor Error
634
Failure Code [CA731] Eng Bkup Speed Sens Phase Error
636
Failure Code [CA757] All Persistent Data Lost Error
638
Failure Code [CA778] Eng Bkup Speed Sensor Error
640
Failure Code [CA1633] KOMNET Datalink Timeout Error
642
Failure Code [CA2185] Throt Sens Sup Volt High Error
644
Failure Code [CA2186] Throt Sens Sup Volt Low Error
645
Failure Code [CA2249] Rail Press very Low Error
646
Failure Code [CA2265] Fuel Feed Pump Open Error
648
Failure Code [CA2266] Fuel Feed Pump Short Error
650
Failure Code [CA2311] IMV Solenoid Error
652
Failure Code [CA2555] Grid Htr Relay Volt Low Error
654
Failure Code [CA2556] Grid Htr Relay Volt High Error
656
Failure Code [D110KB] Battery Relay Drive S/C
658
Failure Code [D19JKZ] Personal Code Relay Abnormality
660
Failure Code [D862KA] GPS Antenna Discon
662
Failure Code [DA22KK] Pump Solenoid Power Low Error
663
Failure Code [DA25KP] 5V Sensor 1 Power Abnormality
665
Failure Code [DA29KQ] Model Selection Abnormality
668
Failure Code [DA2RMC] Pump Comm. Abnormality
670
Failure Code [DAF8KB] Short Circuit in Camera Power Supply
672
Failure Code [DAFGMC] GPS Module Error
674
Troubleshooting by Failure Code (Display of Code), Part
677
Failure Code [DAFRMC] CAN Discon (Monitor Detected)
680
Failure Code [DGH2KB] Hydr Oil Sensor Short
682
Failure Code [DHPAMA] F Pump Press Sensor Abnormality
684
Failure Code [DHPBMA] R Pump Press Sensor Abnormality
686
Failure Code [DHS3MA] Arm Curl PPC Sensor Abnormality
688
Failure Code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
690
Failure Code [DHX1MA] Overload Sensor Abnormality (Analog)
692
Failure Code [DW43KA] Travel Speed Sol. Open Circuit
694
Failure Code [DW43KB] Travel Speed Sol. Short Circuit
696
Failure Code [DW45KA] Swing Brake Sol. Open Circuit
698
Failure Code [DW45KB] Swing Brake Sol. Short Circuit
702
Failure Code [DW91KA] Travel Junction Sol. Open Circuit
704
Failure Code [DW91KB] Travel Junction Sol. Short Circuit
706
Failure Code [DWA2KA] Attachment Sol Open Circuit
708
Failure Code [DWA2KB] Attachment Sol Short Circuit
709
Failure Code [DWJ0KA] Merge-Divider Sol. Open Circuit
710
Failure Code [DWJ0KB] Merge-Divider Sol. Short Circuit
712
Failure Code [DWK0KA] 2-Stage Relief Sol. Open Circuit
714
Failure Code [DWK0KB] 2-Stage Relief Sol. Short Circuit
716
Failure Code [DXA0KA] PC-EPC Sol. Open Circuit
718
Failure Code [DXA0KB] PC-EPC Sol. Short Circuit
720
Failure Code [DXE0KA] LS-EPC Sol. Open Circuit
722
Failure Code [DXE0KB] LS-EPC Sol. Short Circuit
724
Failure Code [DXE4KA] Service Current EPC Open Circuit
726
Failure Code [DXE4KB] Service Current EPC Short Circuit
727
Failure Code [DY20KA] Wiper Working Abnormality
728
Failure Code [DY20MA] Wiper Parking Abnormality
730
Failure Code [DY2CKA] Washer Drive Open Circuit
732
Failure Code [DY2CKB] Washer Drive Short Circuit
734
Failure Code [DY2DKB] Wiper Drive (Fwd) Short Circuit
736
Failure Code [DY2EKB] Wiper Drive (Rev) Short Circuit
738
Before Carrying out Troubleshooting of Electrical System
744
Information Contained in Troubleshooting Table
746
Engine Does Not Start
747
Auto-Decelerator Does Not Operate
750
Automatic Warming-Up System Does Not Operate
752
Preheater Does Not Operate
754
All Work Equipment, Swing, and Travel Mechanism Do Not Move
756
Power Maximizing Function Does Not Operate
758
Machine Monitor Does Not Display at All
760
Contents of Display by Machine Monitor Are Different from Applicable Machine
762
Machine Monitor Does Not Display some Items
762
Fuel Level Monitor was Lighted in Red While Engine Running
763
Engine Coolant Temperature Gauge Does Not Indicate Normally
764
Hydraulic Oil Temperature Gauge Does Not Indicate Normally
766
Fuel Level Gauge Does Not Indicate Normally
767
Swing Lock Monitor Does Not Indicate Normally
768
When Monitor Switch Is Operated, Monitor Displays Nothing
770
Windshield Wiper and Window Washer Do Not Operate
772
Machine Push-Up Function Does Not Operate Normally
776
Monitoring Function Fails to Display "Boom Raise" Normally
778
Monitoring Function Fails to Display "Boom Lower" Normally
780
Monitoring Function Fails to Display "Arm IN" Normally
782
Monitoring Function Fails to Display "Arm OUT" Normally
784
Monitoring Function Fails to Display "Bucket CURL" Normally
786
Monitoring Function Fails to Display "Bucket DUMP" Normally
788
Monitoring Function Fails to Display "Swing" Normally
790
Monitoring Function Fails to Display "Travel" Normally
792
Monitoring Function Fails to Display "Travel Differential Pressure" Normally
794
Monitoring Function Fails to Display "Service" Normally
796
KOMTRAX System Does Not Operate Normally
798
Air Conditioner Does Not Operate
800
Travel Alarm Does Not Sound or Does Not Stop Sounding
802
Horn Does Not Sound
804
System Chart for Hydraulic and Mechanical System
810
Information Contained in Troubleshooting Table
812
All Work Equipment Lack Power, or Travel and Swing Speeds Are Slow
814
Engine Speed Sharply Drops or Engine Stalls
816
No Work Equipment, Swing or Travel Move
817
Abnormal Noise Is Heard from Around Hydraulic Pump
817
Auto-Decelerator Does Not Work
818
Fine Control Mode Does Not Function or Responds Slow
818
Boom Moves Slowly or Lacks Power
819
Arm Moves Slowly or Lacks Power
820
Bucket Moves Slowly or Lacks Power
821
Work Equipment Does Not Move in Its Single Operation
821
Work Equipment Has a Bit too Fast Hydraulic Drift
822
Work Equipment Has Big Time Lag
824
Other Work Equipment Moves When Relieving Single Circuit
824
Power Max. Switch Does Not Operate
825
In Compound Operation, Work Equipment with Larger Load Moves Slowly
825
In Swing + Boom RAISE Operation, Boom Moves Slowly
826
In Swing + Travel Operation, Travel Speed Drops Sharply
826
Machine Swerves in Travel
827
Machine Travels Slowly
828
Machine Cannot be Easily Steered or Lacks Power
829
Travel Speed Does Not Shift, or It Is too Slow or Fast
830
Track Shoe Does Not Turn (on One Side Only)
831
Machine Does Not Swing
832
Swing Acceleration Is Poor, or Swing Speed Is Slow
834
Excessive Overrun When Stopping Swing
836
There Is Big Shock When Stopping Swing
837
Large Sound Is Made When Upper Structure Stops Swinging
837
Swing Hydraulic Drift Is too Big
838
Method of Using Troubleshooting Chart
843
Starting Performance Is Poor
846
Engine Does Not Start
847
Engine Does Not Pick up Smoothly
850
Engine Stops During Operations
851
Engine Does Not Rotate Smoothly
852
Engine Lacks Output (or Lacks Power)
853
Exhaust Smoke Is Black (Incomplete Combustion)
854
Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)
855
Oil Becomes Contaminated Quickly
856
Fuel Consumption Is Excessive
857
Oil Is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
858
Oil Pressure Drops
859
Oil Level Rises (Entry of Coolant or Fuel)
860
Coolant Temperature Becomes too High (Overheating)
861
Abnormal Noise Is Made
862
Vibration Is Excessive
863
Disassembly and Assembly
865
How to Read this Manual
866
Coating Materials List
868
Special Tool List
871
Sketches of Special Tools
874
Removal and Installation of Fuel Supply Pump Assembly
880
Removal and Installation of Engine Front Seal
883
Removal and Installation of Engine Rear Seal
886
Removal and Installation of Cylinder Head Assembly
891
Removal and Installation of Radiator Assembly
904
Removal and Installation of Hydraulic Oil Cooler Assembly
906
Removal and Installation of Aftercooler Assembly
908
Removal and Installation of Engine and Hydraulic Pump Assembly
909
Removal and Installation of Final Drive Assembly
916
Disassembly and Assembly of Final Drive Assembly
917
Removal and Installation of Swing Motor and Swing Machinery Assembly
925
Disassembly and Assembly of Swing Motor and Swing Machinery Assembly
926
Removal and Installation of Swing Circle Assembly
933
Disassembly and Assembly of Carrier Roller
936
Disassembly and Assembly of Track Roller Assembly
937
Disassembly and Assembly of Idler Assembly
938
Disassembly and Assembly of Recoil Spring
941
Removal and Installation of Sprocket
943
Expansion and Installation of Track Shoe Assembly
944
Removal and Installation of Revolving Frame Assembly
946
Removal and Installation of Counterweight Assembly
948
Removal and Installation of Center Swivel Joint Assembly
954
Disassembly and Assembly of Center Swivel Joint Assembly
956
Removal and Installation of Hydraulic Tank Assembly
957
Disassembly and Assembly of Control Valve Assembly
962
Removal and Installation of Hydraulic Pump Assembly
963
Removal and Installation of Oil Seal in Hydraulic Pump Input Shaft
965
Disassembly and Assembly of Work Equipment PPC Valve Assembly
966
Disassembly and Assembly of Travel PPC Valve Assembly
968
Disassembly and Assembly of Hydraulic Cylinder Assembly
971
Removal and Installation of Work Equipment Assembly
978
Removal and Installation of Operator's Cab Assembly
984
Removal and Installation of Operator Cab Glass (Stuck Glass)
987
Removal and Installation of Front Window Assembly
997
Removal and Installation of Floor Frame Assembly
1004
Removal and Installation of Air Conditioner Unit Assembly
1010
Removal and Installation of KOMTRAX Communication Modem Assembly
1013
Removal and Installation of Monitor Assembly
1014
Removal and Installation of Pump Controller Assembly
1016
Removal and Installation of Engine Controller
1018
Diagrams and Drawings
1021
Hydraulic Circuit Diagram
1023
Electrical Circuit Diagram
1026
Connector List and Sterogram
1026
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