TÀI LIỆU – SHOP MANUAL KOMATSU PC300-8 & PC350

00 Index and foreword
Index SEN01985-03
Composition of shop manual ……………………………………………………………………………………… 2
Table of contents………………………………………………………………………………………………………. 4
Foreword and general information SEN01986-00
Safety notice……………………………………………………………………………………………………………….. 2
How to read the shop manual ………………………………………………………………………………………..7
Explanation of terms for maintenance standard……………………………………………………………….. 9
Handling of electric equipment and hydraulic component………………………………………………….. 11
Handling of connectors newly used for engines……………………………………………………………….. 20
How to read electric wire code………………………………………………………………………………………. 23
Precautions when carrying out operation ………………………………………………………………………… 26
Method of disassembling and connecting push-pull type coupler ……………………………………….. 29
Standard tightening torque table ……………………………………………………………………………………. 32
Conversion table …………………………………………………………………………………………………………. 36
01 Specification
Specification and technical data SEN01988-01
Specification dimension drawings ………………………………………………………………………………….. 2
Dimensions…………………………………………………………………………………………………………………. 2
Working ranges …………………………………………………………………………………………………………… 3
Specifications ……………………………………………………………………………………………………………… 4
Weight table ……………………………………………………………………………………………………………….. 10
Table of fuel, coolant and lubricants ……………………………………………………………………………….. 12
10 Structure, function and maintenance standard
Engine and cooling system SEN01990-00
Engine related parts …………………………………………………………………………………………………….. 2
Radiator, oil cooler and aftercooler…………………………………………………………………………………. 3
Power train SEN01991-00
Power train …………………………………………………………………………………………………………………. 2
Swing circle ………………………………………………………………………………………………………………… 3
Swing machinery …………………………………………………………………………………………………………. 4
Final drive…………………………………………………………………………………………………………………… 6
Sprocket …………………………………………………………………………………………………………………….. 8
Undercarriage and frame SEN01992-00
Track frame and recoil spring ………………………………………………………………………………………… 2
Idler …………………………………………………………………………………………………………………………… 4
Carrier roller ……………………………………………………………………………………………………………….. 6
Track roller………………………………………………………………………………………………………………….. 7
Track shoe………………………………………………………………………………………………………………….. 8
Hydraulic system, Part 1 SEN01993-00
Hydraulic equipment layout drawing ………………………………………………………………………………. 2
Hydraulic tank and filter ………………………………………………………………………………………………… 4
Hydraulic pump …………………………………………………………………………………………………………… 6
Hydraulic system, Part 2 SEN01994-00
Control valve ………………………………………………………………………………………………………………. 2
CLSS …………………………………………………………………………………………………………………………. 14
Outline of CLSS…………………………………………………………………………………………………………… 14
Basic principle …………………………………………………………………………………………………………….. 15
Functions and operation by valve……………………………………………………………………………………18
Hydraulic circuit diagram and the name of valves…………………………………………………………….. 18
Unload valve……………………………………………………………………………………………………………….. 20
00 Index and foreword SEN01985-03
PC300, 350-8 5
Introduction of LS pressure …………………………………………………………………………………………… 22
LS bypass plug……………………………………………………………………………………………………………. 23
Pressure compensation valve ………………………………………………………………………………………..24
Pressure compensation valve inner shuttle valve …………………………………………………………….. 27
Boom regeneration circuit …………………………………………………………………………………………….. 29
Arm regeneration circuit ……………………………………………………………………………………………….. 31
Merge-divider valve……………………………………………………………………………………………………… 33
LS select valve ……………………………………………………………………………………………………………. 35
Self pressure reducing valve…………………………………………………………………………………………. 36
Travel junction valve…………………………………………………………………………………………………….. 39
Travel PPC shuttle valve ………………………………………………………………………………………………. 41
Boom drift prevention valve…………………………………………………………………………………………… 43
Arm drift prevention valve …………………………………………………………………………………………….. 46
Quick return valve ……………………………………………………………………………………………………….. 50
Lift check valve……………………………………………………………………………………………………………. 52
Main relief valve ………………………………………………………………………………………………………….. 53
2-stage safety-suction valve………………………………………………………………………………………….. 54
Variable pressure compensation valve …………………………………………………………………………… 56
Attachment circuit selector valve……………………………………………………………………………………. 58
Hydraulic drift prevention valve ……………………………………………………………………………………… 60
Hydraulic system, Part 3 SEN01995-00
Valve control……………………………………………………………………………………………………………….. 2
PPC valve ………………………………………………………………………………………………………………….. 4
Solenoid valve…………………………………………………………………………………………………………….. 26
PPC accumulator ………………………………………………………………………………………………………… 28
Return oil filter …………………………………………………………………………………………………………….. 29
Center swivel joint ……………………………………………………………………………………………………….. 30
Travel motor ……………………………………………………………………………………………………………….. 31
Swing motor ……………………………………………………………………………………………………………….. 43
Hydraulic cylinder ………………………………………………………………………………………………………… 52
Work equipment SEN01996-01
Work equipment ………………………………………………………………………………………………………….. 2
Dimensions of components …………………………………………………………………………………………… 4
Cab and its attachments SEN01997-00
Air conditioner piping……………………………………………………………………………………………………. 2
Electrical system SEN01998-00
Engine control …………………………………………………………………………………………………………….. 2
Electronic control system ……………………………………………………………………………………………… 11
Monitor system……………………………………………………………………………………………………………. 36
Sensor ……………………………………………………………………………………………………………………….. 63
KOMTRAX terminal system ………………………………………………………………………………………….. 66
20 Standard value table
Standard service value table SEN02624-00
Standard value table for engine related parts…………………………………………………………………… 2
Standard value table for chassis related parts…………………………………………………………………. 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN02625-00
Tools for testing, adjusting and troubleshooting ……………………………………………………………….. 3
Measuring engine speed………………………………………………………………………………………………. 7
Measuring air boost pressure………………………………………………………………………………………… 8
Measuring exhaust gas color ………………………………………………………………………………………… 9
Adjusting valve clearance …………………………………………………………………………………………….. 11
Measuring compression pressure ………………………………………………………………………………….. 13
Measuring blow-by pressure …………………………………………………………………………………………. 17
SEN01985-03 00 Index and foreword
6 PC300, 350-8
Measuring engine oil pressure ………………………………………………………………………………………. 18
Measuring fuel pressure……………………………………………………………………………………………….. 19
Handling during cylinder cut-out operation………………………………………………………………………. 23
Handling during no injection cranking operation ………………………………………………………………. 23
Measuring fuel return rate and leakage…………………………………………………………………………… 24
Bleeding air from fuel circuit………………………………………………………………………………………….. 26
Checking fuel circuit for leakage ……………………………………………………………………………………. 27
Testing and adjusting air compressor belt tension ……………………………………………………………. 28
Measuring clearance in swing circle bearings………………………………………………………………….. 29
Testing and adjusting track shoe tension ………………………………………………………………………… 30
Testing and adjusting oil pressurein work equipment, swing and travel circuit …………………….. 31
Testing and adjusting control circuit oil pressure………………………………………………………………. 35
Testing and adjusting pump PC control circuit oil pressure………………………………………………… 36
Testing and adjusting pump LS control circuit oil pressure ………………………………………………… 39
Measuring solenoid valve output pressure………………………………………………………………………. 44
Measuring PPC valve output pressure……………………………………………………………………………. 48
Adjusting play of work equipment and swing PPC valves………………………………………………….. 49
Inspecting locations of hydraulic drift of workequipment …………………………………………………… 50
Releasing remaining pressure in hydraulic circuit …………………………………………………………….. 52
Measuring oil leakage amount ……………………………………………………………………………………….52
Bleeding air from various parts………………………………………………………………………………………. 55
Diode inspection procedures…………………………………………………………………………………………. 57
Testing and adjusting, Part 2 SEN02626-00
Special functions of machine monitor……………………………………………………………………………… 2
Testing and adjusting, Part 3 SEN02663-00
Handling voltage circuit of engine controller…………………………………………………………………….. 2
Preparation work for troubleshooting of electrical system………………………………………………….. 3
Procedure for testing diodes …………………………………………………………………………………………. 7
Pm clinic service………………………………………………………………………………………………………….. 8
40 Troubleshooting
Failure code table and fuse locations SEN02627-00
Failure codes table ………………………………………………………………………………………………………. 2
Fuse locations …………………………………………………………………………………………………………….. 5
General information on troubleshooting SEN02628-00
Points to remember when troubleshooting………………………………………………………………………. 2
Sequence of events in troubleshooting …………………………………………………………………………… 3
Checks before troubleshooting………………………………………………………………………………………. 4
Classification and troubleshooting steps …………………………………………………………………………. 5
Information in troubleshooting table ………………………………………………………………………………..6
Connection table for connector pin numbers……………………………………………………………………. 11
T-adapter box and T-adapter table …………………………………………………………………………………. 45
Troubleshooting by failure code (Display of code), Part 1 SEN02629-00
Failure code [A000N1] Eng. Hi Out of Std……………………………………………………………………….. 3
Failure code [AA10NX] Air cleaner Clogging …………………………………………………………………… 4
Failure code [AB00KE] Charge Voltage Low……………………………………………………………………. 6
Failure code [B@BAZG] Eng Oil Press. Low …………………………………………………………………… 8
Failure code [B@BAZK] Eng Oil Level Low …………………………………………………………………….. 10
Failure code [B@BCNS] Eng. Water Overheat………………………………………………………………… 12
Failure code [B@BCZK] Eng Water Level Low………………………………………………………………… 14
Failure code [B@HANS] Hydr Oil Overheat…………………………………………………………………….. 16
Failure code [CA111] EMC Critical Internal Failure …………………………………………………………… 17
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ……………………………………………….. 17
Failure code [CA122] Chg Air Press Sensor High Error…………………………………………………….. 18
Failure code [CA123] Chg Air Press Sensor Low Error …………………………………………………….. 20
Failure code [CA131] Throttle Sensor High Error……………………………………………………………… 22
Failure code [CA132] Throttle Sensor Low Error ……………………………………………………………… 2