Komatsu PC300-5 Custom, PC400-5 Custom Hydraulic Excavator Shop Manual SEBM0207C503

Description

• Model List:
  • PC300-5 Custom Hydraulic Excavator
  • PC400-5 Custom Hydraulic Excavator

• 1. COVER
• 2. CONTENTS
• 3. STRUCTURE AND FUNCTION
• 3.1. POWER TRAIN
• 3.2. FINAL DRIVE
• 3.3. SWING CIRCLE
• 3.4. SWING MACHINERY
• 3.5. TRACK FRAME AND RECOIL SPRING
• 3.6. IDLER
• 3.7. TRACK ROLLER, CARRIER ROLLER
• 3.8. TRACK SHOE
• 3.9. HYDRAULIC PIPING
• 3.10. HYDRAULIC CIRCUIT DIAGRAM
• 3.11. HYDRAULIC TANK
• 3.12. HYDRAULIC PUMP
• 3.13. CONTROL VALVE
• 3.14. SWING MOTOR
• 3.15. CENTER SWIVEL JOINT
• 3.16. TRAVEL MOTOR
• 3.17. VALVE CONTROL
• 3.18. PPC VALVE
• 3.19. ACCUMULATOR, SAFETY LOCK VALVE
• 3.20. SOLENOID VALVE ASSEMBLY
• 3.21. SHUTTLE VALVE
• 3.22. HYDRAULIC CYLINDER
• 3.23. ELECTRICAL WIRING DIAGRAM
• 3.24. ELECTRICAL CIRCUIT DIAGRAM
• 3.25. ENGINE CONTROL SYSTEM
• 3.26. GOVERNOR MOTOR LINKAGE
• 3.27. OLSS SYSTEM
• 3.28. EMACC
• 4. TESTING AND ADJUSTING
• 4.1. TABLE OF JUDGEMENT STANDARD VALUE
• 4.2. STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
• 4.3. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 4.4. ADJUSTING VALVE CLEARANCE
• 4.5. MEASURING COMPRESSION PRESSURE
• 4.6. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 4.7. TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER
• 4.8. ADJUSTING FUEL CONTROL LEVER
• 4.9. INSPECTION OF SWING CIRCLE BEARING CLEARANCE
• 4.10. TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
• 4.11. TESTING AND ADJUSTING CHARGING PUMP PRESSURE
• 4.12. TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE
• 4.13. TESTING AND ADJUSTING TRAVEL DEVIATION
• 4.14. MEASURING OUTPUT PRESSURE OF PPC VALVE
• 4.15. ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
• 4.16. MEASURING SOLENOID VALVE OUTLET PORT PRESSURE
• 4.17. TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
• 4.18. BLEEDING AIR
• 4.19. TROUBLESHOOTING
• 4.19.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 4.19.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 4.19.3. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 4.19.4. HANDLING CONNECTORS
• 4.19.5. CHECKS BEFORE TROUBLESHOOTING
• 4.19.6. ELECTRICAL CIRCUIT DIAGRAM
• 4.19.7. POSITION OF CONNECTORS FOR TROUBLESHOOTING
• 4.19.8. CONNECTION TABLE FOR CONNECTOR
• 4.19.9. DISPLAY METHOD FOR MONITOR PANEL AND ENGINE THROTTLE CONTROLLER
• 4.19.10. ACTION OF SELFDIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE
• 4.19.11. METHOD OF USING JUDGEMENT TABLE
• 4.19.12. METHOD OF USING TROUBLESHOOTING CHARTS
• 4.19.13. TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)
• 4.19.14. TROUBLESHOOTING OF SOLENOID CIRCUIT (C MODE)
• 4.19.15. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
• 4.19.16. TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)
• 5. DISASSEMBLY AND ASSEMBLY
• 5.1. METHOD OF USING MANUAL
• 5.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 5.3. SPECIAL TOOL LIST
• 5.4. WEIGHT TABLE
• 5.5. TIGHTENING TORQUES AND STANDARD VALUES TABLE
• 5.6. LUBRICANT AND COOLANT TABLE
• 5.7. STARTING MOTOR
• 5.7.1. REMOVAL AND INSTALLATION
• 5.8. ALTERNATOR
• 5.8.1. REMOVAL AND INSTALLATION
• 5.9. ENGINE OIL COOLER
• 5.9.1. REMOVAL AND INSTALLATION
• 5.10. FUEL INJECTION PUMP
• 5.10.1. REMOVAL AND INSTALLATION
• 5.11. WATER PUMP
• 5.11.1. REMOVAL AND INSTALLATION
• 5.12. NOZZLE HOLDER
• 5.12.1. REMOVAL AND INSTALLATION
• 5.13. TURBOCHARGER
• 5.13.1. REMOVAL AND INSTALLATION
• 5.14. THERMOSTAT
• 5.14.1. REMOVAL AND INSTALLATION
• 5.15. ENGINE FRONT OIL SEAL
• 5.15.1. REMOVAL AND INSTALLATION
• 5.16. ENGINE REAR OIL SEAL
• 5.16.1. REMOVAL AND INSTALLATION
• 5.17. GOVERNOR MOTOR
• 5.17.1. REMOVAL AND INSTALLATION
• 5.18. CYLINDER HEAD
• 5.18.1. REMOVAL AND INSTALLATION (PC300)
• 5.18.2. REMOVAL AND INSTALLATION (PC400)
• 5.19. AFTERCOOLER CORE
• 5.19.1. REMOVAL AND INSTALLATION (PC300)
• 5.20. HYDRAULIC COOLER
• 5.20.1. REMOVAL AND INSTALLATION
• 5.21. RADIATOR, HYDRAULIC OIL COOLER
• 5.21.1. REMOVAL AND INSTALLATION
• 5.22. ENGINE, HYDRAULIC PUMP
• 5.22.1. REMOVAL AND INSTALLATION (PC300)
• 5.22.2. REMOVAL (PC400)
• 5.22.3. INSTALLATION (PC400)
• 5.23. DAMPER
• 5.23.1. REMOVAL AND INSTALLATION
• 5.24. CENTER SWIVEL JOINT
• 5.24.1. REMOVAL AND INSTALLATION
• 5.24.2. DISASSEMBLY AND ASSEMBLY
• 5.25. FINAL DRIVE
• 5.25.1. REMOVAL AND INSTALLATION
• 5.25.2. DISASSEMBLY
• 5.25.3. ASSEMBLY
• 5.26. SPROCKET
• 5.26.1. REMOVAL AND INSTALLATION
• 5.27. SWING MOTOR
• 5.27.1. REMOVAL AND INSTALLATION
• 5.28. SWING MACHINERY
• 5.28.1. REMOVAL AND INSTALLATION
• 5.28.2. DISASSEMBLY
• 5.28.3. ASSEMBLY
• 5.29. REVOLVING FRAME
• 5.29.1. REMOVAL AND INSTALLATION
• 5.30. SWING CIRCLE
• 5.30.1. REMOVAL AND INSTALLATION
• 5.31. IDLER, RECOIL SPRING
• 5.31.1. REMOVAL AND INSTALLATION
• 5.32. RECOIL SPRING
• 5.32.1. DISASSEMBLY AND ASSEMBLY
• 5.33. TRACK ROLLER
• 5.33.1. REMOVAL AND INSTALLATION
• 5.34. CARRIER ROLLER
• 5.34.1. REMOVAL AND INSTALLATION
• 5.35. TRACK SHOE
• 5.35.1. REMOVAL AND INSTALLATION
• 5.36. CHARGING PUMP
• 5.36.1. REMOVAL AND INSTALLATION
• 5.37. HYDRAULIC PUMP
• 5.37.1. REMOVAL AND INSTALLATION
• 5.38. HYDRAULIC PUMP INPUT SHAFT OIL SEAL
• 5.38.1. REMOVAL AND INSTALLATION
• 5.39. CONTROL VALVE
• 5.39.1. REMOVAL AND INSTALLATION
• 5.39.2. DISASSEMBLY
• 5.39.3. ASSEMBLY
• 5.40. MAIN RELIEF VALVE
• 5.40.1. REMOVAL AND INSTALLATION
• 5.40.2. DISASSEMBLY AND ASSEMBLY
• 5.41. TVC VALVE
• 5.41.1. REMOVAL AND INSTALLATION
• 5.42. CONC VALVE
• 5.42.1. REMOVAL AND INSTALLATION
• 5.43. SERVO VALVE
• 5.43.1. REMOVAL AND INSTALLATION
• 5.44. WORK EQUIPMENT PPC VALVE
• 5.44.1. REMOVAL AND INSTALLATION
• 5.44.2. DISASSEMBLY AND ASSEMBLY
• 5.45. TRAVEL PPC VALVE
• 5.45.1. REMOVAL AND INSTALLATION
• 5.45.2. DISASSEMBLY AND ASSEMBLY
• 5.46. PPC SHUTTLE VALVE
• 5.46.1. REMOVAL AND INSTALLATION
• 5.47. BOOM CYLINDER
• 5.47.1. PC3005, PC4005 (BACK HOE)
• 5.47.2. REMOVAL AND INSTALLATION
• 5.48. ARM CYLINDER
• 5.48.1. PC3005, PC4005 (BACK HOE)
• 5.48.2. REMOVAL AND INSTALLATION
• 5.49. BUCKET CYLINDER
• 5.49.1. PC3005, PC4005 (BACK HOE)
• 5.49.2. REMOVAL AND INSTALLATION
• 5.50. BOOM CYLINDER
• 5.50.1. PC4005 (LOADING SHOVEL)
• 5.50.2. REMOVAL AND INSTALLATION
• 5.51. ARM CYLINDER
• 5.51.1. PC4005 (LOADING SHOVEL)
• 5.51.2. REMOVAL AND INSTALLATION
• 5.52. BUCKET CYLINDER
• 5.52.1. PC4005 (LOADING SHOVEL)
• 5.52.2. REMOVAL AND INSTALLATION
• 5.53. BOTTOM DUMP CYLINDER
• 5.53.1. PC4005 (LOADING SHOVEL)
• 5.53.2. REMOVAL AND INSTALLATION
• 5.54. HYDRAULIC CYLINDER
• 5.54.1. DISASSEMBLY
• 5.54.2. ASSEMBLY
• 5.55. WORK EQUIPMENT
• 5.55.1. PC3005, PC4005 (BACK HOE)
• 5.55.2. REMOVAL AND INSTALLATION
• 5.56. BUCKET
• 5.56.1. PC3005, PC4005 (BACK HOE)
• 5.56.2. REMOVAL AND INSTALLATION
• 5.57.1. PC3005, PC4005 (BACK HOE)
• 5.57.2. REMOVAL AND INSTALLATION
• 5.58. ARM, BUCKET
• 5.58.1. PC3005, PC4005 (BACK HOE)
• 5.58.2. REMOVAL AND INSTALLATION
• 5.59. BOOM
• 5.59.1. PC3005, PC4005 (BACK HOE)
• 5.59.2. REMOVAL AND INSTALLATION
• 5.60. WORK EQUIPMENT
• 5.60.1. PC4005 (LOADING SHOVEL)
• 5.60.2. REMOVAL AND INSTALLATION
• 5.61. BOOM
• 5.61.1. PC4005 (LOADING SHOVEL)
• 5.61.2. REMOVAL AND INSTALLATION
• 5.62.1. PC4005 (LOADING SHOVEL)
• 5.62.2. REMOVAL AND INSTALLATION
• 5.63. BUCKET
• 5.63.1. PC4005 (LOADING SHOVEL)
• 5.63.2. REMOVAL AND INSTALLATION
• 5.64. OPERATORS CAB
• 5.64.1. REMOVAL AND INSTALLATION
• 5.65. COUNTER WEIGHT
• 5.65.1. REMOVAL AND INSTALLATION
• 5.66. ENGINE THROTTLE CONTROLLER
• 5.66.1. REMOVAL AND INSTALLATION
• 5.67. MONITOR PANEL
• 5.67.1. REMOVAL AND INSTALLATION
• 5.68. PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT
• 5.68.1. PC300
• 5.68.2. PC400
• 6. MAINTENANCE STANDARD
• 6.1. FINAL DRIVE
• 6.2. SWING CIRCLE
• 6.3. SWING MACHINERY
• 6.4. TRACK FRAME AND RECOIL SPRING
• 6.5. CHARGING PUMP AND RELIEF VALVE
• 6.6. CONTROL VALVE
• 6.7. TRAVEL SHUTTLE VALVE
• 6.8. SWING MOTOR
• 6.9. CENTER SWIVEL JOINT
• 6.10. TRAVEL MOTOR
• 6.11. PPC VALVE
• 6.12. PPC SHUTTLE VALVE
• 6.13. HYDRAULIC CYLINDER
• 6.14. WORK EQUIPMENT