Komatsu Hydraulic Excavator Pc300 8 Shop Manual

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SEN01983-03

HYDRAULIC
EXCAVATOR
PC300 -8

PC300LC -8
PC350 -8

PC350LC -8
PC300- 60001
PC300LC- 60001
SERIAL NUMBERS and up
PC350- 60001
PC350LC- 60001

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 SEN01985-03

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC300-8
PC300LC-8
PC350-8
PC350LC-8

Machine model Serial number

PC300-8 60001 and up
PC300LC-8 60001 and up
PC350-8 60001 and up
PC350LC-8 60001 and up

00 Index and foreword 1

Index

Composition of shop manual .......................................................................................................................... 2

Table of contents ............................................................................................................................................. 4

PC300, 350-8 1
SEN01985-03 00 Index and foreword

Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01983-03

00 Index and foreword SEN01984-03

Index SEN01985-03 q
Foreword and general information SEN01986-00

01 Specification SEN01987-01
Specification and technical data SEN01988-01

10 Structure, function and maintenance standard SEN01989-01

Engine and cooling system SEN01990-00
Power train SEN01991-00
Undercarriage and frame SEN01992-00
Hydraulic system, Part 1 SEN01993-00
Hydraulic system, Part 2 SEN01994-00
Hydraulic system, Part 3 SEN01995-00
Work equipment SEN01996-01
Cab and its attachments SEN01997-00
Electrical system SEN01998-00

20 Standard value table SEN01999-00

Standard service value table SEN02624-00

30 Testing and adjusting SEN02000-00

Testing and adjusting, Part 1 SEN02625-00
Testing and adjusting, Part 2 SEN02626-00
Testing and adjusting, Part 3 SEN02663-00

40 Troubleshooting SEN02001-00
Failure code table and fuse locations SEN02627-00
General information on troubleshooting SEN02628-00
Troubleshooting by failure code (Display of code), Part 1 SEN02629-00
Troubleshooting by failure code (Display of code), Part 2 SEN02630-00
Troubleshooting by failure code (Display of code), Part 3 SEN02631-00
Troubleshooting of electrical system (E-mode) SEN02632-00
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02633-00

2 PC300, 350-8
00 Index and foreword SEN01985-03

Troubleshooting of engine (S-mode) SEN02634-00

50 Disassembly and assembly SEN02002-00

General information on disassembly and assembly SEN02635-00 Q
Engine and cooling system SEN02636-00 Q
Power train SEN02637-00 Q
Undercarriage and frame SEN02638-00 Q
Hydraulic system SEN02639-00 Q
Work equipment SEN02640-00 Q
Cab and its attachments SEN02641-00 Q
Electrical system SEN02642-00 Q

90 Diagrams and drawings SEN02003-01

Hydraulic diagrams and drawings SEN02004-00
Electrical diagrams and drawings SEN02005-01

PC300, 350-8 3
SEN01985-03 00 Index and foreword

Table of contents 1
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

4 PC300, 350-8
00 Index and foreword SEN01985-03

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

PC300, 350-8 5
SEN01985-03 00 Index and foreword

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 pressure in 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 work equipment ............................................................ 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 ........................................................................ 24

6 PC300, 350-8
00 Index and foreword SEN01985-03

Failure code [CA144] Coolant Temp Sens High Error................................................................. 26

Failure code [CA145] Coolant Temp Sens Low Error ................................................................. 28
Failure code [CA153] Chg Air Temp Sensor High Error.............................................................. 30
Failure code [CA154] Chg Air Temp Sensor Low Error............................................................... 32
Failure code [CA187] Sens Supply 2 Volt Low Error................................................................... 34
Failure code [CA221] Ambient Press Sens High Error ............................................................... 36
Failure code [CA222] Ambient Press Sens Low Error ................................................................ 38
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................. 40
Failure code [CA234] Eng Overspeed ........................................................................................ 41
Failure code [CA238] Ne Speed Sens Supply Volt Error ............................................................ 42
Failure code [CA271] IMV/PCV1 Short Error .............................................................................. 43
Failure code [CA272] IMV/PCV1 Open Error.............................................................................. 44
Failure code [CA322] Inj #1 Open/Short Error ............................................................................ 46
Failure code [CA323] Inj #5 Open/Short Error ............................................................................ 48
Failure code [CA324] Inj #3 Open/Short Error ............................................................................ 50
Failure code [CA325] Inj #6 Open/Short Error ............................................................................ 52
Failure code [CA331] Inj #2 Open/Short Error ............................................................................ 54
Failure code [CA332] Inj #4 Open/Short Error ............................................................................ 56
Troubleshooting by failure code (Display of code), Part 2 SEN02630-00
Failure code [CA342] Calibration Code Incompatibility ............................................................... 3
Failure code [CA351] Injectors Drive Circuit Error ...................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error................................................................... 6
Failure code [CA386] Sens Supply 1 Volt High Error.................................................................. 8
Failure code [CA428] Water in Fuel Sensor High Error .............................................................. 10
Failure code [CA429] Water in Fuel Sensor Low Error ............................................................... 12
Failure code [CA441] Battery Voltage Low Error ........................................................................ 14
Failure code [CA442] Battery Voltage High Error........................................................................ 16
Failure code [CA449] Rail Press Very High Error ....................................................................... 18
Failure code [CA451] Rail Press Sensor High Error ................................................................... 22
Failure code [CA452] Rail Press Sensor Low Error .................................................................... 24
Failure code [CA553] Rail Press High Error................................................................................ 26
Failure code [CA559] Rail Press Low Error ................................................................................ 27
Failure code [CA689] Eng Ne Speed Sensor Error..................................................................... 29
Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................... 31
Failure code [CA757] All Persistent Data Lost Error ................................................................... 32
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................. 34
Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................... 36
Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................. 38
Failure code [CA2186] Throt Sens Sup Volt Low Error............................................................... 39
Failure code [CA2249] Rail Press Very Low Error ...................................................................... 40
Failure code [CA2265] Electric Lift Pump High Error .................................................................. 42
Failure code [CA2266] Electric Lift Pump Low Error ................................................................... 44
Failure code [CA2555] Grid Htr Relay Volt High Error ................................................................ 46
Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................. 48
Failure code [D110KB] Battery Relay Drive S/C ......................................................................... 50
Failure code [DA25KP] 5V sensor 1 power abnormality ............................................................. 52
Failure code [DA2RMC] Pump Comm. Abnormality ................................................................... 56
Failure code [DA2SKQ] Model Selection Abnormality ................................................................ 58
Troubleshooting by failure code (Display of code), Part 3 SEN02631-00
Failure code [DAFRMC] CAN discon (Monitor detected) ............................................................ 4
Failure code [DHPAMA] F Pump Press Sensor Abnormality ...................................................... 6
Failure code [DHPBMA] R Pump Press Sensor Abnormality ..................................................... 8
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality .......................................................... 10
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ........................................ 12
Failure code [DW43KA] Travel Speed Sol. Disc. ........................................................................ 14
Failure code [DW43KB] Travel Speed Sol. S/C .......................................................................... 16
Failure code [DW45KA] Swing Brake Sol. Disc. ......................................................................... 18
Failure code [DW45KB] Swing Brake Sol. S/C ........................................................................... 22

PC300, 350-8 7
SEN01985-03 00 Index and foreword

Failure code [DW91KA] Travel Junction Sol. Disc. ..................................................................... 24

Failure code [DW91KB] Travel Junction Sol. S/C ....................................................................... 26
Failure code [DWJ0KA] Merge-divider Sol. Disc......................................................................... 28
Failure code [DWJ0KB] Merge-divider Sol. S/C.......................................................................... 30
Failure code [DWK0KA] 2-stage Relief Sol. Disc. ....................................................................... 32
Failure code [DWK0KB] 2-stage Relief Sol. S/C ......................................................................... 34
Failure code [DXA0KA] PC-EPC Sol. Disc.................................................................................. 36
Failure code [DXA0KB] PC-EPC Sol. S/C................................................................................... 38
Failure code [DXE0KA] LS-EPC Sol. Disc. ................................................................................. 40
Failure code [DXE0KB] LS-EPC Sol. S/C ................................................................................... 42
Failure code [DXE4KA] Service Current EPC Disc. .................................................................... 44
Failure code [DXE4KB] Service Current EPC S/C ...................................................................... 45
Failure code [DY20KA] Wiper Working Abnormality ................................................................... 46
Failure code [DY20MA] Wiper Parking Abnormality.................................................................... 48
Failure code [DY2CKB] Washer Drive Short ............................................................................... 50
Failure code [DY2DKB] Wiper Drive (For) Short ......................................................................... 52
Failure code [DY2EKB] Wiper Drive (Rev) Short ........................................................................ 54
Troubleshooting of electrical system (E-mode) SEN02632-00
Before carrying out troubleshooting of electrical system............................................................. 4
Information contained in troubleshooting table............................................................................ 6
E-1 Engine does not start............................................................................................................ 7
E-2 Auto-decelerator does not operate ....................................................................................... 10
E-3 Automatic warming-up system does not operate.................................................................. 12
E-4 Preheater does not operate .................................................................................................. 14
E-5 All work equipment, swing, and travel mechanism do not move .......................................... 16
E-6 Power maximizing function does not operate ....................................................................... 18
E-7 Machine monitor does not display at all................................................................................ 20
E-8 Machine monitor does not display some items..................................................................... 22
E-9 Contents of display by machine monitor are different from applicable machine................... 22
E-10 Fuel level monitor was lighted in red while engine running ................................................ 23
E-11 Engine coolant temperature gauge does not indicate normally .......................................... 24
E-12 Hydraulic oil temperature gauge does not indicate normally .............................................. 26
E-13 Fuel level gauge does not indicate normally....................................................................... 27
E-14 Swing lock monitor does not indicate normally................................................................... 28
E-15 When monitor switch is operated, monitor displays nothing............................................... 30
E-16 Windshield wiper and window washer do not operate........................................................ 32
E-17 Machine push-up function does not operate normally ........................................................ 36
E-18 Monitoring function fails to display “boom raise” normally .................................................. 38
E-19 Monitoring function fails to display “boom lower” normally ................................................. 40
E-20 Monitoring function fails to display “arm IN” normally ......................................................... 42
E-21 Monitoring function fails to display “arm OUT” normally ..................................................... 44
E-22 Monitoring function fails to display “bucket CURL” normally .............................................. 46
E-23 Monitoring function fails to display “bucket DUMP” normally.............................................. 48
E-24 Monitoring function fails to display “swing” normally........................................................... 50
E-25 Monitoring function fails to display “travel” normally ........................................................... 52
E-26 Monitoring function fails to display “travel differential pressure” normally .......................... 54
E-27 Monitoring function fails to display “service” normally ........................................................ 56
E-28 KOMTRAX system does not operate normally ................................................................... 58
E-29 Air conditioner does not operate......................................................................................... 60
E-30 Travel alarm does not sound or does not stop sounding .................................................... 62
E-31 Horn does not sound .......................................................................................................... 64
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02633-00
System chart for hydraulic and mechanical system .................................................................... 4
Information contained in troubleshooting table............................................................................ 6
H-1 All work equipment lack power, or travel and swing speeds are slow .................................. 8
H-2 Engine speed sharply drops or engine stalls ........................................................................ 10
H-3 No work equipment, swing or travel move............................................................................ 11
H-4 Abnormal noise is heard from around hydraulic pump ......................................................... 11

8 PC300, 350-8
00 Index and foreword SEN01985-03

H-5 Auto-decelerator does not work ........................................................................................... 12

H-6 Fine control mode does not function or responds slow ........................................................ 12
H-7 Boom moves slowly or lacks power ..................................................................................... 13
H-8 Arm moves slowly or lacks power ........................................................................................ 14
H-9 Bucket moves slowly or lacks power.................................................................................... 15
H-10 Work equipment does not move in its single operation ...................................................... 15
H-11 Work equipment has a bit too fast hydraulic drift................................................................ 16
H-12 Work equipment has big time lag ....................................................................................... 18
H-13 Other work equipment moves when relieving single circuit................................................ 18
H-14 Power max. switch does not operate ................................................................................. 19
H-15 In compound operation, work equipment with larger load moves slowly ........................... 19
H-16 In swing + boom RAISE operation, boom moves slowly .................................................... 20
H-17 In swing + travel operation, travel speed drops sharply ..................................................... 20
H-18 Machine swerves in travel .................................................................................................. 21
H-19 Machine travels slowly ....................................................................................................... 22
H-20 Machine cannot be easily steered or lacks power.............................................................. 23
H-21 Travel speed does not shift, or it is too slow or fast............................................................ 24
H-22 Track shoe does not turn (on one side only) ...................................................................... 25
H-23 Machine does not swing..................................................................................................... 26
H-24 Swing acceleration is poor, or swing speed is slow............................................................ 28
H-25 Excessive overrun when stopping swing............................................................................ 30
H-26 There is big shock when stopping swing............................................................................ 31
H-27 Large sound is made when upper structure stops swinging. ............................................. 31
H-28 Swing hydraulic drift is too big ............................................................................................ 32
Troubleshooting of engine (S-mode) SEN02634-00
Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance is poor ................................................................................................ 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 15
S-9 Oil becomes contaminated quickly ....................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................... 21
S-15 Abnormal noise is made ..................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................... 23

50 Disassembly and assembly

General information on disassembly and assembly SEN02635-00
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tools list........................................................................................................................... 7
Sketches of special tools............................................................................................................. 11
Engine and cooling system SEN02636-00
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of engine front seal ............................................................................. 5
Removal and installation of engine rear seal .............................................................................. 7
Removal and installation of cylinder head assembly .................................................................. 12
Removal and installation of radiator assembly............................................................................ 24
Removal and installation of hydraulic oil cooler assembly .......................................................... 26
Removal and installation of aftercooler assembly ....................................................................... 28

PC300, 350-8 9
SEN01985-03 00 Index and foreword

Removal and installation of engine and hydraulic pump assembly ............................................. 29

Power train SEN02637-00
Removal and installation of final drive assembly......................................................................... 2
Disassembly and assembly of final drive assembly .................................................................... 3
Removal and installation of swing motor and swing machinery assembly .................................. 11
Disassembly and assembly of swing motor and swing machinery assembly ............................. 12
Removal and installation of swing circle assembly ..................................................................... 19
Undercarriage and frame SEN02638-00
Disassembly and assembly of carrier roller................................................................................. 2
Disassembly and assembly of track roller assembly................................................................... 3
Disassembly and assembly of idler assembly............................................................................. 4
Disassembly and assembly of recoil spring ................................................................................ 7
Removal and installation of sprocket........................................................................................... 9
Expansion and installation of track shoe assembly ..................................................................... 10
Removal and installation of revolving frame assembly ............................................................... 11
Removal and installation of counterweight assembly.................................................................. 13
Hydraulic system SEN02639-00
Removal and installation of center swivel joint assembly............................................................ 2
Disassembly and assembly of center swivel joint assembly ....................................................... 4
Removal and installation of hydraulic tank assembly .................................................................. 5
Removal and installation of control valve assembly .................................................................... 7
Disassembly and assembly of control valve assembly ............................................................... 10
Removal and installation of hydraulic pump assembly................................................................ 12
Removal and installation of oil seal in hydraulic pump input shaft .............................................. 14
Disassembly and assembly of work equipment PPC valve assembly ........................................ 15
Disassembly and assembly of travel PPC valve assembly ......................................................... 16
Disassembly and assembly of hydraulic cylinder assembly........................................................ 17
Work equipment SEN02640-00
Removal and installation of work equipment assembly............................................................... 2
Cab and its attachments SEN02641-00
Removal and installation of operator's cab assembly ................................................................. 2
Removal and installation of operator cab glass (stuck glass) ..................................................... 5
Removal and installation of front window assembly .................................................................... 15
Removal and installation of floor frame assembly ....................................................................... 22
Electrical system SEN02642-00
Removal and installation of air conditioner unit assembly........................................................... 2
Removal and installation of KOMTRAX communication modem assembly ................................ 5
Removal and installation of monitor assembly ............................................................................ 6
Removal and installation of pump controller assembly ............................................................... 8
Removal and installation of engine controller.............................................................................. 10

90 Diagrams and drawings

Hydraulic diagrams and drawings SEN02004-00
Hydraulic circuit diagram ............................................................................................................. 3
Electrical diagrams and drawings SEN02005-01
Electrical circuit diagram ............................................................................................................. 3
Connector arrangement diagram ................................................................................................ 5

10 PC300, 350-8
00 Index and foreword SEN01985-03

PC300, 350-8 11
SEN01985-03

PC300, 350(LC)-8 Hydraulic excavator

Form No. SEN01985-03

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 08-07 (01)

12
 SEN01986-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

PC300-8
PC300LC-8
PC350-8
PC350LC-8

Machine model Serial number

PC300-8 60001 and up
PC300LC-8 60001 and up
PC350-8 60001 and up
PC350LC-8 60001 and up

00 Index and foreword 1

Foreword and general information
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

PC300, 350-8 1
SEN01986-00 00 Index and foreword

Safety notice 1 (Rev. 2007/03)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.

1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.

2 PC300, 350-8
00 Index and foreword SEN01986-00

3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.

PC300, 350-8 3
SEN01986-00 00 Index and foreword

4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

4 PC300, 350-8
00 Index and foreword SEN01986-00

q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.

PC300, 350-8 5
Komatsu Hydraulic Excavator Pc300 8 Shop Manual
Full download: http://manualplace.com/download/komatsu-hydraulic-excavator-pc300-8-shop-manual/
SEN01986-00 00 Index and foreword

8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refriger-
ant (R134a) from the air condi-
tioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.

2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.

a Example of O-ring (Fitted to every joint of

hoses and tubes)

a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".

6 PC300, 350-8

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