Komatsu Galeo PC300-8, PC300LC-8, PC350-8, PC350LC-8 Hydraulic Excavator Service Manual
990 pages · Publication SEN01983-03
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What's inside
From the manual's own table of contents: 181 sections, 335 entries. See sample pages (PDF, 1098 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification dimension drawings
Dimensions
Working ranges
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine related parts
Radiator, oil cooler and aftercooler
Power train
Swing circle
Swing machinery
Final drive
Sprocket
Show all 181 sections
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Hydraulic equipment layout drawing
Hydraulic tank and filter
Hydraulic pump
Control valve
CLSS
Outline of CLSS
Basic principle
Functions and operation by valve
Hydraulic circuit diagram and the name of valves
Unload valve46 topics
- Introduction of LS pressure
- LS bypass plug
- Pressure compensation valve
- Pressure compensation valve inner shuttle valve
- Boom regeneration circuit
- Arm regeneration circuit
- Merge-divider valve
- LS select valve
- Self pressure reducing valve
- Travel junction valve
- Travel PPC shuttle valve
- Boom drift prevention valve
- Arm drift prevention valve
- Quick return valve
- Lift check valve
- Main relief valve
- 2-stage safety-suction valve
- Variable pressure compensation valve
- Attachment circuit selector valve
- Hydraulic drift prevention valve
- Valve control
- PPC valve
- Solenoid valve
- PPC accumulator
- Return oil filter
- Center swivel joint
- Travel motor
- Swing motor
- Hydraulic cylinder
- Work equipment
- Dimensions of components
- Air conditioner piping
- Engine control
- Electronic control system
- Monitor system
- Sensor
- KOMTRAX terminal system
- Standard value table for engine related parts
- Standard value table for chassis related parts
- Tools for testing, adjusting and troubleshooting
- Measuring engine speed
- Measuring air boost pressure
- Measuring exhaust gas color
- Adjusting valve clearance
- Measuring compression pressure
- Measuring blow-by pressure
Measuring engine oil pressure
Measuring fuel pressure
Handling during cylinder cut-out operation
Handling during no injection cranking operation
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Testing and adjusting air compressor belt tension
Measuring clearance in swing circle bearings
Testing and adjusting track shoe tension
Testing and adjusting oil pressure in work equipment, swing and travel circuit
Testing and adjusting control circuit oil pressure
Testing and adjusting pump PC control circuit oil pressure
Testing and adjusting pump LS control circuit oil pressure
Measuring solenoid valve output pressure
Measuring PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Inspecting locations of hydraulic drift of work equipment
Releasing remaining pressure in hydraulic circuit
Measuring oil leakage amount
Bleeding air from various parts
Diode inspection procedures
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm clinic service
Failure codes table
Fuse locations
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and troubleshooting steps
Information in troubleshooting table
Connection table for connector pin numbers
T-adapter box and T-adapter table
Failure code [A000N1] Eng. Hi Out of Std
Failure code [AA10NX] Air cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng Oil Press. Low
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BCNS] Eng. Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@HANS] Hydr Oil Overheat
Failure code [CA111] EMC Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error56 topics
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA187] Sens Supply 2 Volt Low Error
- Failure code [CA221] Ambient Press Sens High Error
- Failure code [CA222] Ambient Press Sens Low Error
- Failure code [CA227] Sens Supply 2 Volt High Error
- Failure code [CA234] Eng Overspeed
- Failure code [CA238] Ne Speed Sens Supply Volt Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA322] Inj #1 Open/Short Error
- Failure code [CA323] Inj #5 Open/Short Error
- Failure code [CA324] Inj #3 Open/Short Error
- Failure code [CA325] Inj #6 Open/Short Error
- Failure code [CA331] Inj #2 Open/Short Error
- Failure code [CA332] Inj #4 Open/Short Error
- Failure code [CA342] Calibration Code Incompatibility
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sens Supply 1 Volt Low Error
- Failure code [CA386] Sens Supply 1 Volt High Error
- Failure code [CA428] Water in Fuel Sensor High Error
- Failure code [CA429] Water in Fuel Sensor Low Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA553] Rail Press High Error
- Failure code [CA559] Rail Press Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA757] All Persistent Data Lost Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA1633] KOMNET Datalink Timeout Error
- Failure code [CA2185] Throt Sens Sup Volt High Error
- Failure code [CA2186] Throt Sens Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [CA2265] Electric Lift Pump High Error
- Failure code [CA2266] Electric Lift Pump Low Error
- Failure code [CA2555] Grid Htr Relay Volt High Error
- Failure code [CA2556] Grid Htr Relay Volt Low Error
- Failure code [D110KB] Battery Relay Drive S/C
- Failure code [DA25KP] 5V sensor 1 power abnormality
- Failure code [DA2RMC] Pump Comm. Abnormality
- Failure code [DA2SKQ] Model Selection Abnormality
- Failure code [DAFRMC] CAN discon (Monitor detected)
- Failure code [DHPAMA] F Pump Press Sensor Abnormality
- Failure code [DHPBMA] R Pump Press Sensor Abnormality
- Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality
- Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
- Failure code [DW43KA] Travel Speed Sol. Disc
- Failure code [DW43KB] Travel Speed Sol. S/C
- Failure code [DW45KA] Swing Brake Sol. Disc
- Failure code [DW45KB] Swing Brake Sol. S/C
Failure code [DW91KA] Travel Junction Sol. Disc
Failure code [DW91KB] Travel Junction Sol. S/C
Failure code [DWJ0KA] Merge-divider Sol. Disc
Failure code [DWJ0KB] Merge-divider Sol. S/C
Failure code [DWK0KA] 2-stage Relief Sol. Disc
Failure code [DWK0KB] 2-stage Relief Sol. S/C
Failure code [DXA0KA] PC-EPC Sol. Disc
Failure code [DXA0KB] PC-EPC Sol. S/C
Failure code [DXE0KA] LS-EPC Sol. Disc
Failure code [DXE0KB] LS-EPC Sol. S/C
Failure code [DXE4KA] Service Current EPC Disc
Failure code [DXE4KB] Service Current EPC S/C
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive Short
Failure code [DY2DKB] Wiper Drive (For) Short
Failure code [DY2EKB] Wiper Drive (Rev) Short
Before carrying out troubleshooting of electrical system
Information contained in troubleshooting table
Engine does not start
Auto-decelerator does not operate
Automatic warming-up system does not operate
Preheater does not operate
All work equipment, swing, and travel mechanism do not move
Power maximizing function does not operate
Machine monitor does not display at all
Machine monitor does not display some items
Contents of display by machine monitor are different from applicable machine
Fuel level monitor was lighted in red while engine running
Engine coolant temperature gauge does not indicate normally
Hydraulic oil temperature gauge does not indicate normally
Fuel level gauge does not indicate normally
Swing lock monitor does not indicate normally
When monitor switch is operated, monitor displays nothing
Windshield wiper and window washer do not operate
Machine push-up function does not operate normally
Monitoring function fails to display “boom raise” normally
Monitoring function fails to display “boom lower” normally
Monitoring function fails to display “arm IN” normally
Monitoring function fails to display “arm OUT” normally
Monitoring function fails to display “bucket CURL” normally
Monitoring function fails to display “bucket DUMP” normally
Monitoring function fails to display “swing” normally
Monitoring function fails to display “travel” normally
Monitoring function fails to display “travel differential pressure” normally
Monitoring function fails to display “service” normally
KOMTRAX system does not operate normally
Air conditioner does not operate
Travel alarm does not sound or does not stop sounding
Horn does not sound
System chart for hydraulic and mechanical system
All work equipment lack power, or travel and swing speeds are slow
Engine speed sharply drops or engine stalls
No work equipment, swing or travel move
Abnormal noise is heard from around hydraulic pump52 topics
- Auto-decelerator does not work
- Fine control mode does not function or responds slow
- Boom moves slowly or lacks power
- Arm moves slowly or lacks power
- Bucket moves slowly or lacks power
- Work equipment does not move in its single operation
- Work equipment has a bit too fast hydraulic drift
- Work equipment has big time lag
- Other work equipment moves when relieving single circuit
- Power max. switch does not operate
- In compound operation, work equipment with larger load moves slowly
- In swing + boom RAISE operation, boom moves slowly
- In swing + travel operation, travel speed drops sharply
- Machine swerves in travel
- Machine travels slowly
- Machine cannot be easily steered or lacks power
- Travel speed does not shift, or it is too slow or fast
- Track shoe does not turn (on one side only)
- Machine does not swing
- Swing acceleration is poor, or swing speed is slow
- Excessive overrun when stopping swing
- There is big shock when stopping swing
- Large sound is made when upper structure stops swinging
- Swing hydraulic drift is too big
- Method of using troubleshooting chart
- Starting performance is poor
- Engine does not start
- Engine does not pick up smoothly
- Engine stops during operations
- Engine does not rotate smoothly
- Engine lacks output (or lacks power)
- Exhaust smoke is black (incomplete combustion)
- Oil consumption is excessive (or exhaust smoke is blue)
- Oil becomes contaminated quickly
- Fuel consumption is excessive
- Oil is in coolant (or coolant spurts back or coolant level goes down)
- Oil pressure drops
- Oil level rises (Entry of coolant or fuel)
- Coolant temperature becomes too high (overheating)
- Abnormal noise is made
- Vibration is excessive
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Removal and installation of fuel supply pump assembly
- Removal and installation of engine front seal
- Removal and installation of engine rear seal
- Removal and installation of cylinder head assembly
- Removal and installation of radiator assembly
- Removal and installation of hydraulic oil cooler assembly
- Removal and installation of aftercooler assembly
Removal and installation of engine and hydraulic pump assembly
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
Disassembly and assembly of carrier roller
Disassembly and assembly of track roller assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring
Removal and installation of sprocket
Expansion and installation of track shoe assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Removal and installation of hydraulic pump assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Removal and installation of work equipment assembly
Removal and installation of operator's cab assembly
Removal and installation of operator cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Removal and installation of KOMTRAX communication modem assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller
Hydraulic circuit diagram
Electrical circuit diagram
Connector arrangement diagram
Inside this manual
Real pages from this service manual (990 pages). Open the sample pages (PDF, 1098 KB)
- Specifications, page 402: 30 Testing and adjusting
- Diagram, page 597: Failure code [CA428] Water in Fuel Sensor High Error
- Troubleshooting, page 657: Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality
- Foldout diagram, page 983: Electrical circuit diagram
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 990 pages
Quantity one is the manual described above.
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Other editions and similar models
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