Komatsu HYDRAULIC EXCAVATOR Galeo PC350LC-8 PC350LCD-8 PC350NLC-8 PC350NLCD-8 Shop Manual UEN01983-00

1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.

2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc.

4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.

5) Only qualified workers must carry out work and operation which require license or qualification.

6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. 8) Before starting work, warm up your body thoroughly to start work under good condition.

00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
00 Index and foreword 13
Foreword and general information 13
Safety notice 14
How to read the shop manual 19
Explanation of terms for maintenance standard 21
Handling electric equipment and hydraulic component 23
How to read electric wire code 35
Precautions when carrying out operation 38
Method of disassembling and connecting push-pull type coupler 41
Standard tightening torque table 44
Conversion table 48
01 Specification 55
Specification and technical data 55
Specification dimension drawings 56
Specifications 58
Weight table 61
Table of fuel, coolant and lubricants 62
10 Structure, function and maintenance standard 65
Engine and cooling system 65
Engine related parts 66
Radiator, oil cooler and aftercooler 67
10 Structure, function and maintenance standard 69
Power train 69
Power train 70
Final drive 72
Sprocket 74
Swing machinery 76
Swing circle 78
10 Structure, function and maintenance standard 81
Undercarriage and frame 81
Track frame and recoil spring 82
Idler 84
Carrier roller 86
Track roller 87
Track shoe 88
10 Structure, function and maintenance standard 93
Hydraulic system, Part 1 93
Hydraulic equipment layout drawing 94
Hydraulic tank and filter 96
Hydraulic pump 98
10 Structure, function and maintenance standard123
Hydraulic system, Part 2123
Control valve124
CLSS136
Functions and operation by valve140
Merge-divider valve155
Attachment circuit selector valve180
Hydraulic drift prevention valve182
10 Structure, function and maintenance standard189
Hydraulic system, Part 3189
Valve control190
PPC valve192
Solenoid valve214
PPC accumulator216
Return oil filter217
Center swivel joint218
Travel motor219
Swing motor231
Hydraulic cylinder240
10 Structure, function and maintenance standard243
Work equipment243
Work equipment244
Work equipment244
Dimensions of components246
10 Structure, function and maintenance standard251
Cab and its attachments251
Air conditioner piping252
10 Structure, function and maintenance standard255
Electrical system255
Engine control256
Electronic control system265
Monitor system290
Sensor317
KOMTRAX terminal system320
20 Standard value table323
Standard service value table323
Standard value table for engine related parts324
Standard value table for chassis related parts325
30 Testing and adjusting337
Testing and adjusting, Part 1337
Tools for testing, adjusting and troubleshooting339
Measuring engine speed343
Measuring air boost pressure344
Measuring exhaust gas color345
Adjusting valve clearance347
Measuring compression pressure349
Measuring blow-by pressure353
Measuring engine oil pressure354
Measuring fuel pressure355
Handling during cylinder cut-out operation359
Handling during no injection cranking operation359
Measuring fuel return rate and leakage360
Bleeding air from fuel circuit362
Checking fuel circuit for leakage363
Testing and adjusting air compressor belt tension364
Measuring clearance in swing circle bearings365
Testing and adjusting track shoe tension366
Testing and adjusting oil pressure in work equipment, swing and travel circuit367
Testing and adjusting control circuit oil pressure371
Testing and adjusting pump PC control circuit oil pressure372
Testing and adjusting pump LS control circuit oil pressure375
Measuring solenoid valve output pressure380
Measuring PPC valve output pressure384
Adjusting play of work equipment and swing PPC valves385
Inspecting locations of hydraulic drift of work equipment386
Releasing remaining pressure in hydraulic circuit388
Measuring oil leakage amount388
Bleeding air from various parts391
Diode inspection procedures393
30 Testing and adjusting395
Testing and adjusting, Part 2395
Special functions of machine monitor396
30 Testing and adjusting453
Testing and adjusting, Part 3453
Handling voltage circuit of engine controller454
Preparation work for troubleshooting of electrical system455
Procedure for testing diodes459
Pm clinic service460
40 Troubleshooting467
Failure code table and fuse locations467
Failure codes table468
Fuse locations471
40 Troubleshooting477
General information on troubleshooting477
Points to remember when troubleshooting478
Sequence of events in troubleshooting479
Checks before troubleshooting480
Classification and troubleshooting steps481
Information in troubleshooting table482
Connection table for connector pin numbers487
T-adapter box and T-adapter table521
40 Troubleshooting525
Troubleshooting by failure code (Display of code), Part 1525
Failure code [A000N1] Eng Hi Out of Std527
Failure code [AA10NX] Air cleaner Clogging528
Failure code [AB00KE] Charge Voltage Low530
Failure code [B@BAZG] Eng Oil Press Low532
Failure code [B@BAZK] Eng Oil Level Low534
Failure code [B@BCNS] Eng Water Overheat536
Failure code [B@BCZK] Eng Water Level Low538
Failure code [B@HANS] Hydr Oil Overheat540
Failure code [CA111] EMC Critical Internal Failure541
Failure code [CA115] Eng Ne and Bkup Speed Sens Error541
Failure code [CA122] Chg Air Press Sensor High Error542
Failure code [CA123] Chg Air Press Sensor Low Error544
Failure code [CA131] Throttle Sensor High Error546
Failure code [CA132] Throttle Sensor Low Error548
Failure code [CA144] Coolant Temp Sens High Error550
Failure code [CA145] Coolant Temp Sens Low Error552
Failure code [CA153] Chg Air Temp Sensor High Error554
Failure code [CA154] Chg Air Temp Sensor Low Error556
Failure code [CA187] Sens Supply 2 Volt Low Error558
Failure code [CA221] Ambient Press Sens High Error560
Failure code [CA222] Ambient Press Sens Low Error562
Failure code [CA227] Sens Supply 2 Volt High Error564
Failure code [CA234] Eng Overspeed565
Failure code [CA238] Ne Speed Sens Supply Volt Error566
Failure code [CA271] IMV/PCV1 Short Error567
Failure code [CA272] IMV/PCV1 Open Error568
Failure code [CA322] Inj #1 Open/Short Error570
Failure code [CA323] Inj #5 Open/Short Error572
Failure code [CA324] Inj #3 Open/Short Error574
Failure code [CA325] Inj #6 Open/Short Error576
Failure code [CA331] Inj #2 Open/Short Error578
Failure code [CA332] Inj #4 Open/Short Error580
40 Troubleshooting583
Troubleshooting by failure code (Display of code), Part 2583
Failure code [CA342] Calibration Code Incompatibility585
Failure code [CA351] Injectors Drive Circuit Error586
Failure code [CA352] Sens Supply 1 Volt Low Error588
Failure code [CA386] Sens Supply 1 Volt High Error590
Failure code [CA428] Water in Fuel Sensor High Error592
Failure code [CA429] Water in Fuel Sensor Low Error594
Failure code [CA441] Battery Voltage Low Error596
Failure code [CA442] Battery Voltage High Error598
Failure code [CA449] Rail Press Very High Error600
Failure code [CA451] Rail Press Sensor High Error604
Failure code [CA452] Rail Press Sensor Low Error606
Failure code [CA553] Rail Press High Error608
Failure code [CA559] Rail Press Low Error609
Failure code [CA689] Eng Ne Speed Sensor Error611
Failure code [CA731] Eng Bkup Speed Sens Phase Error613
Failure code [CA757] All Persistent Data Lost Error614
Failure code [CA778] Eng Bkup Speed Sensor Error616
Failure code [CA1633] KOMNET Datalink Timeout Error618
Failure code [CA2185] Throt Sens Sup Volt High Error620
Failure code [CA2186] Throt Sens Sup Volt Low Error621
Failure code [CA2249] Rail Press Very Low Error622
Failure code [CA2265] Electric Lift Pump High Error624
Failure code [CA2266] Electric Lift Pump Low Error626
Failure code [CA2555] Grid Htr Relay Volt High Error628
Failure code [CA2556] Grid Htr Relay Volt Low Error630
Failure code [D110KB] Battery Relay Drive S/C632
Failure code [DA25KP] 5V sensor 1 power abnormality634
Failure code [DA2RMC] Pump Comm Abnormality638
Failure code [DA2SKQ] Model Selection Abnormality640
40 Troubleshooting643
Troubleshooting by failure code (Display of code), Part 3643
Failure code [DAFRMC] CAN discon (Monitor detected)646
Failure code [DHPAMA] F Pump Press Sensor Abnormality648
Failure code [DHPBMA] R Pump Press Sensor Abnormality650
Failure code [DHS3MA] Arm Curl PPC Sen Abnormality652
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality654
Failure code [DW43KA] Travel Speed Sol Disc656
Failure code [DW43KB] Travel Speed Sol S/C658
Failure code [DW45KA] Swing Brake Sol Disc660
Failure code [DW45KB] Swing Brake Sol S/C664
Failure code [DW91KA] Travel Junction Sol Disc666
Failure code [DW91KB] Travel Junction Sol S/C668
Failure code [DWJ0KA] Merge-divider Sol Disc670
Failure code [DWJ0KB] Merge-divider Sol S/C672
Failure code [DWK0KA] 2-stage Relief Sol Disc674
Failure code [DWK0KB] 2-stage Relief Sol S/C676
Failure code [DXA0KA] PC-EPC Sol Disc678
Failure code [DXA0KB] PC-EPC Sol S/C680
Failure code [DXE0KA] LS-EPC Sol Disc682
Failure code [DXE0KB] LS-EPC Sol S/C684
Failure code [DXE4KA] Service Current EPC Disc686
Failure code [DXE4KB] Service Current EPC S/C687
Failure code [DY20KA] Wiper Working Abnormality688
Failure code [DY20MA] Wiper Parking Abnormality690
Failure code [DY2CKB] Washer Drive Short692
Failure code [DY2DKB] Wiper Drive (For) Short694
Failure code [DY2EKB] Wiper Drive (Rev) Short696
40 Troubleshooting699
Troubleshooting of electrical system (E-mode)699
Before carrying out troubleshooting of electrical system702
Information contained in troubleshooting table704
E-1 Engine does not start705
E-2 Auto-decelerator does not operate708
E-3 Automatic warming-up system does not operate710
E-4 Preheater does not operate712
E-5 All work equipment, swing, and travel mechanism do not move714
E-6 Power maximizing function does not operate716
E-7 Machine monitor does not display at all718
E-8 Machine monitor does not display some items720
E-9 Contents of display by machine monitor are different from applicable machine720
E-10 Fuel level monitor was lighted in red while engine running721
E-11 Engine coolant temperature gauge does not indicate normally722
E-12 Hydraulic oil temperature gauge does not indicate normally724
E-13 Fuel level gauge does not indicate normally725
E-14 Swing lock monitor does not indicate normally726
E-15 When monitor switch is operated, monitor displays nothing728
E-16 Windshield wiper and window washer do not operate730
E-17 Machine push-up function does not operate normally734
E-18 Monitoring function fails to display “boom raise” normally736
E-19 Monitoring function fails to display “boom lower” normally738
E-20 Monitoring function fails to display “arm IN” normally740
E-21 Monitoring function fails to display “arm OUT” normally742
E-22 Monitoring function fails to display “bucket CURL” normally744
E-23 Monitoring function fails to display “bucket DUMP” normally746
E-24 Monitoring function fails to display “swing” normally748
E-25 Monitoring function fails to display “travel” normally750
E-26 Monitoring function fails to display “travel differential pressure” normally752
E-27 Monitoring function fails to display “service” normally754
E-28 KOMTRAX system does not operate normally756
E-29 Air conditioner does not operate758
E-30 Travel alarm does not sound or does not stop sounding760
E-31 Horn does not sound762
40 Troubleshooting765
Troubleshooting of hydraulic and mechanical system (H-mode)765
System chart for hydraulic and mechanical system768
Information contained in troubleshooting table770
H-1 All work equipment lack power, or travel and swing speeds are slow772
H-2 Engine speed sharply drops or engine stalls774
H-3 No work equipment, swing or travel move775
H-4 Abnormal noise is heard from around hydraulic pump775
H-5 Auto-decelerator does not work776
H-6 Fine control mode does not function or responds slow776
H-7 Boom moves slowly or lacks power777
H-8 Arm moves slowly or lacks power778
H-9 Bucket moves slowly or lacks power779
H-10 Work equipment does not move in its single operation779
H-11 Work equipment has a bit too fast hydraulic drift780
H-12 Work equipment has big time lag782
H-13 Other work equipment moves when relieving single circuit782
H-14 Power max switch does not operate783
H-15 In compound operation, work equipment with larger load moves slowly783
H-16 In swing + boom RAISE operation, boom moves slowly784
H-17 In swing + travel operation, travel speed drops sharply784
H-18 Machine swerves in travel785
H-19 Machine travels slowly786
H-20 Machine cannot be easily steered or lacks power787
H-21 Travel speed does not shift, or it is too slow or fast788
H-22 Track shoe does not turn (on one side only)789
H-23 Machine does not swing790
H-24 Swing acceleration is poor, or swing speed is slow792
H-25 Excessive overrun when stopping swing794
H-26 There is big shock when stopping swing795
H-27 Large sound is made when upper structure stops swinging795
H-28 Swing hydraulic drift is too big796
40 Troubleshooting799
Troubleshooting of engine (S-mode)799
Method of using troubleshooting chart801
S-1 Starting performance is poor804
S-2 Engine does not start805
S-3 Engine does not pick up smoothly808
S-4 Engine stops during operations809
S-5 Engine does not rotate smoothly810
S-6 Engine lacks output (or lacks power)811
S-7 Exhaust smoke is black (incomplete combustion)812
S-8 Oil consumption is excessive (or exhaust smoke is blue)813
S-9 Oil becomes contaminated quickly814
S-10 Fuel consumption is excessive815
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)816
S-12 Oil pressure drops817
S-13 Oil level rises (Entry of coolant or fuel)818
S-14 Coolant temperature becomes too high (overheating)819
S-15 Abnormal noise is made820
S-16 Vibration is excessive821
50 Disassembly and assembly823
General information on disassembly and assembly823
How to read this manual824
Coating materials list826
Special tools list829
Sketches of special tools833
50 Disassembly and assembly837
Engine and cooling system837
Removal and installation of fuel supply pump assembly838
Removal and installation of engine front seal841
Removal and installation of engine rear seal843
Removal and installation of cylinder head assembly848
Removal and installation of radiator assembly860
Removal and installation of hydraulic oil cooler assembly862
Removal and installation of aftercooler assembly864
Removal and installation of engine and hydraulic pump assembly865
50 Disassembly and assembly871
Power train871
Removal and installation of final drive assembly872
Disassembly and assembly of final drive assembly873
Removal and installation of swing motor and swing machinery assembly881
Disassembly and assembly of swing motor and swing machinery assembly882
Removal and installation of swing circle assembly889
50 Disassembly and assembly891
Undercarriage and frame891
Disassembly and assembly of carrier roller892
Disassembly and assembly of track roller assembly893
Disassembly and assembly of idler assembly894
Disassembly and assembly of recoil spring897
Removal and installation of sprocket899
Expansion and installation of track shoe assembly900
Removal and installation of revolving frame assembly901
Removal and installation of counterweight assembly903
50 Disassembly and assembly905
Hydraulic system905
Removal and installation of centre swivel joint assembly906
Disassembly and assembly of centre swivel joint assembly908
Removal and installation of hydraulic tank assembly909
Removal and installation of control valve assembly911
Disassembly and assembly of control valve assembly914
Removal and installation of hydraulic pump assembly916
Removal and installation of oil seal in hydraulic pump input shaft918
Disassembly and assembly of work equipment PPC valve assembly919
Disassembly and assembly of travel PPC valve assembly920
Disassembly and assembly of hydraulic cylinder assembly921
50 Disassembly and assembly927
Work equipment927
Removal and installation of work equipment assembly928
50 Disassembly and assembly933
Cab and its attachments933
Removal and installation of operator’s cab assembly934
Removal and installation of operator cab glass (stuck glass)937
Removal and installation of front window assembly947
Removal and installation of floor frame assembly954
50 Disassembly and assembly959
Electrical system959
Removal and installation of air conditioner unit assembly960
Removal and installation of KOMTRAX communication modem assembly963
Removal and installation of monitor assembly964
Removal and installation of pump controller assembly966
Removal and installation of engine controller968
90 Diagrams and drawings971
Hydraulic diagrams and drawings971
Hydraulic circuit diagram 1/2973
Hydraulic circuit diagram 2/2975
90 Diagrams and drawings979
Electrical diagrams and drawings979
Connector arrangement diagram981
Electrical circuit diagrams983
Electrical circuit diagrams985
Electrical circuit diagrams987
Electrical circuit diagrams989
Electrical circuit diagrams991