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Komatsu PC350LC-8, PC350HD-8 Hydraulic Excavator Shop Manual CEBM007501 – PDF DOWNLOAD
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Komatsu PC350LC-8, PC350HD-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS:
PC350LC-8 A10001 and up
PC350HD-8 A00001 and up
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Description
Komatsu PC350LC-8, PC350HD-8 Hydraulic Excavator Shop Manual CEBM007501
FILE DETAILS:
Komatsu PC350LC-8, PC350HD-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC350LC-8, PC350HD-8
Serial Number: A10001 and up, A00001 and up
Book Code: CEBM007501
Language: English
Pages: 1097
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC350LC-8, PC350HD-8 Hydraulic Excavator Shop Manual
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards when inspecting disassembled parts.
STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
TROUBLESHOOTING:
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
AIR CONDITIONING:
This section explains the air conditioning system. The structure, function, maintenance standard, testing, adjusting, troubleshooting, servicing and some disassembly and assembly.
DIAGRAMS AND DRAWINGS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu PC350LC-8, PC350HD-8 Hydraulic Excavator Shop Manual
CEBM007501 - PC350LC-8 / PC350HD-8........................................................... 1 CONTENTS................................................................................. 2 REVISED PAGES............................................................................ 3 SAFETY................................................................................... 13 Safety Notice........................................................................ 13 IMPORTANT SAFETY NOTICE.......................................................... 13 General Precautions.............................................................. 13 Preparations For Work............................................................ 13 Precautions During Work.......................................................... 14 GENERAL.................................................................................. 15 HOW TO READ THE SHOP MANUAL.............................................................. 16 Volumes.............................................................................. 16 Distribution and Updating............................................................ 16 Filing Method........................................................................ 16 Revised Edition Mark................................................................. 16 Revisions............................................................................ 16 Symbols.............................................................................. 16 HOISTING INSTRUCTIONS.................................................................... 17 Hoisting............................................................................. 17 Wire Ropes........................................................................... 17 PUSH PULL COUPLER........................................................................ 18 Type 1............................................................................... 18 Disconnection.................................................................... 18 Connection....................................................................... 18 Type 2............................................................................... 19 Disconnection.................................................................... 19 Connection....................................................................... 19 Type 3............................................................................... 20 Disconnection.................................................................... 20 Connection....................................................................... 20 COATING MATERIALS........................................................................ 21 STANDARD TIGHTENING TORQUE............................................................... 23 Standard Tightening Torque of Bolts And Nuts......................................... 23 Tightening Torque of Hose Nuts....................................................... 24 Tightening Torque of Split Flange Bolts.............................................. 24 Tightening Torque for Flared Nuts.................................................... 24 Table of Tightening Torques for O-ring Boss Piping Joints............................ 25 Table of Tightening Torques for O-ring Boss Plugs.................................... 25 Tightening Torque Table for Hoses (Taper Seal Type and Face Seal Type)............... 25 ELECTRIC WIRE CODE....................................................................... 26 Classification by Thickness.......................................................... 26 Classification by Color and Code..................................................... 26 CONVERSION TABLES........................................................................ 27 Method of Using the Conversion Table................................................. 27 01 GENERAL................................................................................... 33 SPECIFICATION DIMENSION DRAWINGS......................................................... 34 Dimensions........................................................................... 34 Working Ranges....................................................................... 35 SPECIFICATIONS........................................................................... 36 WEIGHT TABLE............................................................................. 39 FUEL, COOLANT, AND LUBRICANTS............................................................ 41 10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD............................................... 43 ENGINE AND COOLING SYSTEM................................................................ 46 Engine Related Parts................................................................. 46 Radiator, Oil Cooler and Aftercooler................................................. 47 POWER TRAIN.............................................................................. 48 Power Train.......................................................................... 48 Final Drive.......................................................................... 50 PC350LC-8........................................................................ 50 PC350HD-8........................................................................ 52 Sprocket............................................................................. 54 PC350LC-8........................................................................ 54 PC350HD-8........................................................................ 56 Swing Machinery...................................................................... 58 Swing Circle......................................................................... 60 UNDERCARRIAGE AND FRAME.................................................................. 62 Track Frame and Recoil Spring........................................................ 62 PC350LC-8........................................................................ 62 PC350HD-8........................................................................ 64 Idler................................................................................ 66 PC350LC-8........................................................................ 66 PC350HD-8........................................................................ 68 Carrier Roller....................................................................... 70 PC350LC-8........................................................................ 70 PC350HD-8........................................................................ 71 Track Roller......................................................................... 72 PC350LC-8........................................................................ 72 PC350HD-8........................................................................ 74 Track Shoe........................................................................... 76 PC350LC-8........................................................................ 76 PC350HD-8........................................................................ 78 Triple Grouser Shoe.................................................................. 80 PC350LC-8........................................................................ 80 PC350HD-8........................................................................ 81 HYDRAULIC SYSTEM......................................................................... 82 Hydraulic Equipment Layout Drawing................................................... 82 Hydraulic Tank and Filter............................................................ 84 Hydraulic Pump....................................................................... 86 Type: HPV125+125................................................................. 86 LS Valve......................................................................... 92 PC Valve......................................................................... 97 LS(PC)-EPC Valve................................................................. 104 Variable Volume Valve............................................................ 107 Control Valve........................................................................ 108 CLSS (Closed Center Load Sensing System)............................................. 120 Valve Functions and Operation........................................................ 124 Hydraulic Circuit Diagram and the Name of Valves................................. 124 Unloader Valve................................................................... 126 LS Pressure...................................................................... 128 Pressure Compensation Valve...................................................... 130 Pressure Compensation Valve Inner Shuttle........................................ 133 Boom Regeneration Circuit........................................................ 135 Arm Regeneration Circuit......................................................... 137 Merge-divider Valve.............................................................. 139 LS Select Valve.................................................................. 141 Self Pressure Reducing Valve..................................................... 142 Travel Junction Valve............................................................ 145 Travel PPC Shuttle Valve......................................................... 147 Boom Drift Prevention Valve...................................................... 149 Arm Drift Prevention Valve....................................................... 152 Quick Return Valve............................................................... 156 Lift Check Valve................................................................. 158 Main Relief Valve................................................................ 159 2-Stage Safety-suction Valve..................................................... 160 Variable Pressure Compensation Valve............................................. 162 Attachment Circuit Selector Valve................................................ 164 Drift Prevention Valve........................................................... 166 Valve Control........................................................................ 171 PPC Valve........................................................................ 172 Travel PPC Valve................................................................. 177 Pressure Reducing Valve.......................................................... 180 Service PPC Valve (with EPC Valve)............................................... 186 Service PPC Valve................................................................ 192 Solenoid Valve................................................................... 194 PPC Accumulator.................................................................. 196 Return Oil Filter................................................................ 197 Center Swivel Joint.............................................................. 198 Travel Motor - Type: HMV160ADT-2 - PC350LC-8..................................... 200 Parking Brake - PC350LC-8........................................................ 206 Travel Motor - Type: KMV200ADT-2 - PC350HD-8..................................... 214 Parking Brake - PC350HD-8........................................................ 220 Safety Valve..................................................................... 224 Swing Motor...................................................................... 228 Reverse Prevention Valve......................................................... 234 Hydraulic Cylinder................................................................... 238 Boom Cylinder.................................................................... 238 Arm Cylinder..................................................................... 238 Bucket Cylinder.................................................................. 238 WORK EQUIPMENT........................................................................... 240 Work Equipment....................................................................... 240 Dimension Of Arm................................................................. 242 Dimension Of Bucket.............................................................. 244 AIR CONDITIONER PIPING................................................................... 246 ELECTRICAL SYSTEM........................................................................ 247 Engine Control....................................................................... 247 Fuel Control Dial................................................................ 249 Engine Controller................................................................ 250 Sensors.............................................................................. 254 Coolant Temperature Sensor....................................................... 254 Oil Pressure Switch.............................................................. 254 Engine Speed Sensor.............................................................. 255 Boost Pressure And Temperature Sensor............................................ 255 WIF (Water-in-fuel Detection) Sensor............................................. 256 Engine Oil Level Sensor.......................................................... 256 ELECTRONIC CONTROL SYSTEM................................................................ 257 Control Function..................................................................... 257 System Diagram....................................................................... 258 Engine and Pump Control.............................................................. 260 Pump and Valve Control............................................................... 266 LS Control Function.............................................................. 267 Cut-off Function................................................................. 267 2-Stage Relief Function.......................................................... 267 Power Maximizing and Machine Push-up................................................. 268 Auto-deceleration.................................................................... 270 Auto-warm-up and Overheat Prevention................................................. 272 Swing Control........................................................................ 274 Travel Control....................................................................... 276 Attachment Flow Control and Circuit Selector......................................... 278 System Component Parts............................................................... 279 PPC Oil Pressure Switch.......................................................... 279 Oil Pressure Sensor.............................................................. 280 Pump Pressure Sensor (High Pressure)............................................. 281 Pump Controller.................................................................. 282 MONITOR SYSTEM........................................................................... 285 Machine Monitor...................................................................... 286 Monitor Control, Display Portion................................................. 290 Monitor Items And Display........................................................ 292 Switches......................................................................... 296 Sensors.......................................................................... 313 KOMTRAX Terminal System.................................................................. 315 KOMTRAX Communication Modem - TH300.................................................. 316 20 STANDARD VALUE TABLES..................................................................... 317 STANDARD VALUE TABLES.................................................................... 318 Engine Related....................................................................... 318 Chassis Related...................................................................... 319 30 TESTING AND ADJUSTING..................................................................... 327 CHASSIS SERVICE TOOLS‘................................................................... 329 Sketches of special tools............................................................ 333 ENGINE................................................................................... 334 Engine Speed......................................................................... 334 Air Boost Pressure................................................................... 335 Exhaust Gas Color.................................................................... 336 Valve Clearance...................................................................... 338 Compression Pressure................................................................. 340 Blow-by Pressure..................................................................... 345 Engine Oil Pressure.................................................................. 346 Fuel Pressure........................................................................ 347 Handling During Cylinder Cut-out Operation........................................... 352 Handling During No Injection Cranking Operation...................................... 352 Fuel Return Rate And Leakage......................................................... 353 Bleeding Air From Fuel Circuit....................................................... 356 Fuel Circuit For Leakage............................................................. 357 AIR COMPRESSOR BELT TENSION.............................................................. 358 FAN BELT................................................................................. 359 ALTERNATOR BELT.......................................................................... 360 SWING CIRCLE BEARINGS.................................................................... 361 TRACK SHOE TENSION....................................................................... 362 OIL PRESSURE IN WORK EQUIPMENT........................................................... 363 OIL PRESSURE IN SWING.................................................................... 363 OIL PRESSURE IN TRAVEL CIRCUIT........................................................... 363 CONTROL CIRCUIT OIL PRESSURE............................................................. 368 PUMP PC OIL PRESSURE..................................................................... 369 PUMP LS OIL PRESSURE..................................................................... 372 SOLENOID VALVE OUTPUT PRESSURE........................................................... 377 PPC VALVE OUTPUT PRESSURE................................................................ 380 WORK EQUIPMENT VALVE ADJUSTMENT.......................................................... 381 SWING PPC VALVE ADJUSTMENT............................................................... 381 HYDRAULIC DRIFT IN WORK EQUIPMENT........................................................ 382 Boom and Bucket Cylinders............................................................ 382 Arm Cylinder......................................................................... 382 Boom Lock Valve...................................................................... 383 PPC Valve............................................................................ 383 RELEASING HYDRAULIC PRESSURE............................................................. 384 Oil Leakage Amount................................................................... 384 BLEEDING AIR FROM VARIOUS SYSTEMS........................................................ 387 DIODE INSPECTION PROCEDURES.............................................................. 390 MACHINE MONITOR - SPECIAL FUNCTIONS...................................................... 392 Ordinary Functions and Special Functions of Machine Monitor.......................... 394 Operator Mode (Outline).............................................................. 396 Display of Komatsu Logo.......................................................... 397 Display of Inputting Password.................................................... 397 Display of Check of Breaker Mode................................................. 398 Display of Check Before Starting................................................. 398 Display of Warning After Check Before Starting................................... 398 Display of Ending of Maintenance Interval........................................ 399 Display of Check of Working Mode and Travel Speed................................ 399 Display of Ordinary Screen....................................................... 399 Display of End Screen............................................................ 400 Selection of Auto-deceleration................................................... 400 Selection of Working Mode........................................................ 400 Selection of Travel Speed........................................................ 401 Operation to Stop Alarm Buzzer................................................... 401 Operation of Windshield Wiper.................................................... 402 Operation of Window Washer....................................................... 402 Operation of Air Conditioner/heater.............................................. 402 Operation to Display Camera Mode (if CameraiIs Installed)........................ 403 Operation to Display Clock and Service Meter..................................... 403 Check of Maintenance Information................................................. 404 Setting and Display of User Mode................................................. 404 KOMTRAX Message.................................................................. 405 Display of Energy-saving Guidance................................................ 405 Display of Caution Monitor....................................................... 405 Display of Automatic Judgment of Breaker......................................... 406 Display of User Code and Failure Code............................................ 406 Function of Checking Display of LCD (Liquid Crystal Display)..................... 408 Function of Checking Service Meter............................................... 408 Function of Changing Attachment/Maintenance Password............................. 409 Service Mode......................................................................... 411 Monitoring....................................................................... 413 Abnormality Record (Mechanical Systems).......................................... 418 Abnormality Record (Electrical Systems).......................................... 419 Abnormality Record (Air-conditioning System/Heater System)....................... 427 Maintenance Record............................................................... 428 Maintenance Mode Change.......................................................... 429 Phone Number Entry............................................................... 432 Default (Key-ON Mode)............................................................ 433 Default (Unit)................................................................... 434 Default (With/Without Attachment)................................................ 435 Default (Attachment/Maintenance Password)........................................ 436 Default (Camera)................................................................. 437 Default (ECO Display)............................................................ 438 Default (Breaker Detect)......................................................... 440 Adjustment (Pump Absorption Torque).............................................. 441 Adjustment (Low Speed)........................................................... 442 Adjustment (Attachment Flow Adjustment).......................................... 443 Cylinder Cut-Out................................................................. 444 No Injection..................................................................... 445 Fuel Consumption................................................................. 447 KOMTRAX Settings (Terminal Status)............................................... 448 KOMTRAX Settings (GPS & Communication Status).................................... 449 KOMTRAX Setting (Modem S/N: TH300)............................................... 450 Display of KOMTRAX Service Message............................................... 451 Long Distance Transport Mode......................................................... 452 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER............................................ 454 PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM................................ 455 PROCEDURE FOR TESTING DIODES............................................................. 460 PM CLINIC SERVICE........................................................................ 461 40 TROUBLESHOOTING........................................................................... 467 FAILURE CODES TABLE...................................................................... 471 FUSE LOCATIONS........................................................................... 474 Connection Table of Fuse Box......................................................... 474 Locations of Fusible Links........................................................... 475 Location of Fuse Box and Fuse Numbers................................................ 475 GENERAL INFORMATION...................................................................... 478 Points to Remember when Troubleshooting.............................................. 478 Sequence of Events in Troubleshooting................................................ 480 Handling Electric Equipment and Hydraulic Components................................. 481 Connectors for Tier 3 Engines........................................................ 489 Checks Before Troubleshooting........................................................ 493 Classification and Troubleshooting Steps............................................. 494 Classification of Troubleshooting................................................ 494 Information in Troubleshooting Table............................................. 496 Possible Problems and Troubleshooting No......................................... 498 Connection Table for Connector Pin Numbers........................................... 501 T-adapter Box and T-adapter Table.................................................... 536 FAILURE CODE (DISPLAY OF CODE)........................................................... 539 989L00 - Engine Controller Lock Caution 1............................................ 539 989L00 - Engine Controller Lock Caution 2............................................ 539 989L00 - Engine Controller Lock Caution 3............................................ 540 AA10NX - Air Cleaner Clogging........................................................ 542 AB00KE - Charge Voltage Low.......................................................... 544 B@BAZG - Engine Oil Pressure Low..................................................... 546 B@BAZK - Engine Oil Level Low........................................................ 548 B@BCNS - Engine Coolant Overheat..................................................... 550 B@BCZK - Engine Coolant Level Low.................................................... 552 B@HANS - Hydraulic Oil Overheat...................................................... 554 CA111 - EMC Critical Internal Failure................................................ 556 CA115 - Engine NE and BKUP Speed Sensor Error........................................ 557 CA122 - Charge Air Pressure Sensor High Error........................................ 558 CA123 - Charge Air Pressure Sensor Low Error......................................... 560 CA131 - Throttle Sensor High Error................................................... 562 CA132 - Throttle Sensor Low Error.................................................... 564 CA144 - Coolant Temperature Sensor High Error........................................ 566 CA145 - Coolant Temperature Sensor Low Error......................................... 568 CA153 - Charge Air Temperature Sensor High Error..................................... 570 CA154 - Charge Air Temperature Sensor Low Error...................................... 572 CA155 - Chg Air Temp High Speed Derate............................................... 574 CA187 - Sensor Power Supply Two Volt Low Error....................................... 576 CA221 - Ambient Pressure Sensor High Error........................................... 578 CA222 - Ambient Pressure Sensor Low Error............................................ 580 CA227 - Sensor Supply Two Volt High Error............................................ 582 CA234 - Engine Overspeed............................................................. 584 CA238 - NE Speed Sensor Supply Voltage Error......................................... 585 CA271 - IMV/PCV1 Short Error......................................................... 586 CA272 - IMV/PCV1 Open Error.......................................................... 588 CA281 - Pump Press Balance Error..................................................... 590 CA322 - Injector #1 Open/short Error................................................. 592 CA323 - Injector #5 Open/short Error................................................. 594 CA324 - Injector #3 Open/short Error................................................. 596 CA325 - Injector #6 Open/short Error................................................. 598 CA331 - Injector #2 Open/short Error................................................. 600 CA332 - Injector #4 Open/short Error................................................. 602 CA342 - Calibration Code Incompatibility............................................. 604 CA351 - Injectors Drive Circuit Error................................................ 606 CA352 - Sensor Supply One Volt Low Error............................................. 608 CA386 - Sensor Supply One Volt High Error............................................ 610 CA428 - Water in Fuel Sensor High Error.............................................. 612 CA429 - Water in Fuel Sensor Low Error............................................... 614 CA435 - Eng Oil Press Sw Error....................................................... 616 CA441 - Battery Voltage Low Error.................................................... 618 CA442 - Battery Voltage High Error................................................... 620 CA449 - Rail Pressure Very High Error................................................ 622 CA451 - Rail Pressure Sensor High Error.............................................. 626 CA452 - Rail Pressure Sensor Low Error............................................... 628 CA488 - Chg Air Temp High Torque Derate.............................................. 630 CA553 - Rail Pressure High Error..................................................... 631 CA559 - Rail Pressure Low Error...................................................... 632 CA689 - Engine NE Speed Sensor Error................................................. 634 CA731 - Engine BKUP Speed Sensor Phase Error......................................... 636 CA757 - All Persistent Data Lost Error............................................... 638 CA778 - Engine BKUP Speed Sensor Error............................................... 640 CA1633 - KOMNET Datalink Timeout Error............................................... 642 CA2185 - Throttle Sensor Supply Volt High Error...................................... 644 CA2186 - Throttle Sensor Supply Volt Low Error....................................... 646 CA2249 - Rail Pressure Very Low Error................................................ 647 CA2265 - Electric Lift Pump High Error............................................... 648 CA2266 - Electric Lift Pump Low Error................................................ 650 CA2311 - IMV Solenoid Error.......................................................... 652 CA2555 - Grid Htr Relay Volt High Error.............................................. 654 CA2556 - Grid Htr Relay Volt Low Error............................................... 656 D110KB - Battery Relay Drive Short Circuit........................................... 658 D19JKZ - Personal Code Relay Abnormality............................................. 660 D862KA - GPS Antenna Discon.......................................................... 662 DA22KK - Pump Solenoid Power Low Error............................................... 664 DA25KP - 5 V Sensor 1 Power Abnormality.............................................. 666 DA29KQ - Model Selection Abnormality................................................. 670 DA2RMC - Pump Communication Abnormality.............................................. 672 DAF8KB - Short Circuit in Camera Power Supply........................................ 674 DAFGMC - GPS Module Error............................................................ 676 DAFRMC - CAN Discon (Monitor Detected)............................................... 678 DGH2KB - Hyd Oil Sensor Short........................................................ 680 DHPAMA - F Pump Pressure Sensor Abnormality.......................................... 682 DHPBMA - R Pump Pressure Sensor Abnormality.......................................... 684 DHS3MA - Arm Curl PPC Sensor Abnormality............................................. 686 DHS4MA - Bucket Curl PPC Pressure Sensor Abnormality................................. 688 DHX1MA - Overload Sensor Abnormality (Analog)........................................ 690 DW43KA - Travel Speed Solenoid Disconnection......................................... 692 DW43KB - Travel Speed Solenoid Short Circuit......................................... 694 DW45KA - Swing Brake Solenoid Disconnection.......................................... 696 DW45KB - Swing Brake Solenoid Short Circuit.......................................... 700 DW91KA - Travel Junction Solenoid Disconnection...................................... 702 DW91KB - Travel Junction Solenoid Short Circuit...................................... 704 DWA2KA - Attachment Sol Open Circuit................................................. 706 DWA2KB - Attachment Sol Short Circuit................................................ 707 DWJ0KA - Merge-Divider Solenoid Disconnection........................................ 708 DWJ0KB - Merge-Divider Solenoid Short Circuit........................................ 710 DWK0KA - 2-Stage Relief Sol. Open Circuit............................................ 712 DWK0KB - 2-Stage Relief Solenoid Short Circuit....................................... 714 DXA0KA - PC-EPC Solenoid Open Circuit................................................ 716 DXA0KB - PC-EPC Solenoid Short Circuit............................................... 718 DXE0KA - LS-EPC Solenoid Disconnection............................................... 720 DXE0KB - LS-EPC Solenoid Short Circuit............................................... 722 DXE4KA - Service Current EPC Disconnection........................................... 724 DXE4KB - Service Current EPC Short Circuit........................................... 725 DY20KA - Wiper Working Abnormality................................................... 726 DY20MA - Wiper Parking Abnormality................................................... 728 DY2CKA - Washer Drive Open Circuit................................................... 730 DY2CKB - Washer Drive Short Circuit.................................................. 732 DY2DKB - Wiper Motor Drive Forward System Short...................................... 734 DY2EKB - Wiper Drive Reverse Short Circuit........................................... 736 E-MODE (ELECTRICAL SYSTEM)............................................................... 738 Information Contained in Troubleshooting Table....................................... 738 E-1 Engine Does Not Start............................................................ 740 E-2 Auto-decelerator Does Not Operate................................................ 743 E-3 Automatic Warming-up System Does Not Operate..................................... 745 E-4 Preheater Does Not Operate....................................................... 746 E-5 All Work Equipment, Swing, and Travel Mechanism do not move...................... 748 E-6 Power Maximizing Function Does Not Operate....................................... 750 E-7 Machine Monitor Does Not Display At All.......................................... 752 E-8 Machine Monitor Does Not Display Some Items...................................... 754 E-9 Contents of Display by Machine Monitor are Different from Applicable Machine..... 754 E-10 Fuel Level Monitor Was Lit in Red While Engine Running.......................... 755 E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally..................... 756 E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally...................... 758 E-13 Fuel Level Gauge Does Not Indicate Normally..................................... 759 E-14 Swing Lock Monitor Does Not Indicate Normally................................... 760 E-15 When Monitor Switch is Operated, Monitor Displays Nothing....................... 762 E-16 Windshield Wiper and Window Washer do not Operate............................... 764 E-17 Machine Push-up Function Does Not Operate Normally.............................. 768 E-18 Monitoring Function Fails to Display “Boom Raise” Normally...................... 770 E-19 Monitoring Function Fails to Display “Boom Lower” Normally...................... 772 E-20 Monitoring Function Fails to Display “Arm In” Normally.......................... 774 E-21 Monitoring Function Fails to Display “Arm Out” Normally......................... 776 E-22 Monitoring Function Fails to Display “Bucket Curl” Normally..................... 778 E-23 Monitoring Function Fails to Display “Bucket Dump” Normally..................... 780 E-24 Monitoring Function Fails to Display “Swing” Normally........................... 782 E-25 Monitoring Function Fails to Display “Travel” Normally.......................... 784 E-26 Monitoring Function Fails to Display “Travel Differential Pressure” Normally.... 786 E-27 Monitoring Function Fails to Display “Service” Normally......................... 788 E-28 KOMTRAX System Does Not Operate Normally........................................ 790 E-29 Air Conditioner Does Not Operate................................................ 792 E-30 Travel Alarm Does Not Sound or Does Not Stop Sounding........................... 794 E-31 Horn Does Not Sound............................................................. 796 H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)................................................ 798 System Chart for Hydraulic and Mechanical System..................................... 798 Information Contained in Troubleshooting Table....................................... 800 H-1 All Work Equipment Lack Power, or Travel and Swing Speeds are Slow............... 802 H-2 Engine Speed Sharply Drops or Engine Stalls...................................... 804 H-3 No Work Equipment, Swing or Travel Move.......................................... 805 H-4 Abnormal Noise is Heard from Around Hydraulic Pump............................... 805 H-5 Auto-decelerator Does Not Work................................................... 806 H-6 Fine Control Mode Does Not Function or Responds Slow............................. 806 H-7 Boom Moves Slowly or Lacks Power................................................. 807 H-8 Arm Moves Slowly or Lacks Power.................................................. 808 H-9 Bucket Moves Slowly or Lacks Power............................................... 809 H-10 Work Equipment Does Not Move in its Single Operation............................ 809 H-11 Work Equipment has a bit too Fast Hydraulic Drift............................... 810 H-12 Work Equipment Has Big Time Lag................................................. 812 H-13 Other Work Equipment Moves When Relieving Single Circuit........................ 812 H-14 Power Max. Switch Does Not Operate.............................................. 813 H-15 In Compound Operation, Work Equipment with Larger Load Moves Slowly............. 813 H-16 In Swing + Boom Raise Operation, Boom Moves Slowly.............................. 814 H-17 In Swing + Travel Operation, Travel Speed Drops Sharply......................... 814 H-18 Machine Swerves in Travel....................................................... 815 H-19 Machine Travels Slowly.......................................................... 816 H-20 Machine Cannot Be Easily Steered or Lacks Power................................. 817 H-21 Travel Speed Does Not Shift, or it is too Slow or Fast.......................... 818 H-22 Track Shoe Does Not Turn (On One Side Only)..................................... 819 H-23 Machine Does Not Swing.......................................................... 820 H-24 Swing Acceleration is Poor, or Swing Speed is Slow.............................. 822 H-25 Excessive Overrun When Stopping Swing........................................... 824 H-26 There is Big Shock when Stopping Swing.......................................... 825 H-27 Large Sound is made when Upper Structure Stops Swinging......................... 825 H-28 Swing Hydraulic Drift is too big................................................ 826 50 DISASSEMBLY AND ASSEMBLY.................................................................. 827 HOW TO READ THIS MANUAL.................................................................. 830 SPECIAL TOOLS LIST....................................................................... 833 SKETCHES OF SPECIAL TOOLS................................................................ 837 CONNECTOR REPAIR PROCEDURES.............................................................. 840 Contact Terminal Removal (HD30 Type)................................................. 840 Striping Insulation.................................................................. 841 Crimping Contact Terminal (HD30 Type)................................................ 842 Insertion Of Contact Terminal (HD30 Type)............................................ 843 Contact Terminal Removal (DT Type)................................................... 844 ENGINE COMPONENTS........................................................................ 845 Fuel Supply Pump..................................................................... 845 Removal.......................................................................... 845 Installation..................................................................... 847 Engine Front Seal.................................................................... 849 Removal.............................................................................. 849 Installation..................................................................... 851 Engine Rear Seal..................................................................... 853 Removal.......................................................................... 853 Installation..................................................................... 855 Cylinder Head........................................................................ 859 Removal.......................................................................... 859 Installation..................................................................... 865 RADIATOR................................................................................. 874 Removal.............................................................................. 874 Installation......................................................................... 875 HYDRAULIC OIL COOLER..................................................................... 876 Removal.............................................................................. 876 Installation......................................................................... 877 AFTERCOOLER.............................................................................. 878 Removal.............................................................................. 878 Installation......................................................................... 878 ENGINE AND HYDRAULIC PUMP................................................................ 879 Removal.............................................................................. 879 Installation......................................................................... 884 FINAL DRIVE.............................................................................. 885 Removal.............................................................................. 885 Installation......................................................................... 885 Disassembly.......................................................................... 886 Assembly............................................................................. 891 SWING MOTOR AND SWING MACHINERY.......................................................... 898 Removal.............................................................................. 898 Installation......................................................................... 899 Disassembly.......................................................................... 900 Assembly............................................................................. 904 SWING CIRCLE............................................................................. 910 Removal.............................................................................. 910 Installation......................................................................... 910 CARRIER ROLLER........................................................................... 911 Disassembly.......................................................................... 911 Assembly............................................................................. 911 TRACK ROLLER............................................................................. 913 Disassembly.......................................................................... 913 Assembly............................................................................. 913 IDLER.................................................................................... 915 Disassembly.......................................................................... 915 Assembly............................................................................. 916 RECOIL SPRING............................................................................ 919 Disassembly.......................................................................... 919 Assembly............................................................................. 920 SPROCKET................................................................................. 922 Removal.............................................................................. 922 Installation......................................................................... 922 TRACK SHOE............................................................................... 923 Expansion............................................................................ 923 Installation......................................................................... 924 REVOLVING FRAME.......................................................................... 925 Removal.............................................................................. 925 Installation......................................................................... 927 COUNTERWEIGHT............................................................................ 928 Removal.............................................................................. 928 Installation......................................................................... 929 CENTER SWIVEL JOINT...................................................................... 930 Removal.............................................................................. 930 Installation......................................................................... 931 Disassembly.......................................................................... 932 Assembly............................................................................. 933 HYDRAULIC TANK........................................................................... 934 Removal.............................................................................. 934 Installation......................................................................... 936 CONTROL VALVE............................................................................ 937 Removal.............................................................................. 937 Installation......................................................................... 940 Disassembly.......................................................................... 940 Assembly............................................................................. 940 HYDRAULIC PUMP........................................................................... 943 Removal.............................................................................. 943 Installation......................................................................... 945 Oil Seal in Hydraulic Pump input Shaft............................................... 946 Removal.......................................................................... 946 Installation..................................................................... 946 WORK EQUIPMENT PPC VALVE................................................................. 947 Disassembly.......................................................................... 947 Assembly............................................................................. 947 TRAVEL PPC VALVE......................................................................... 950 Disassembly.......................................................................... 950 Assembly............................................................................. 951 HYDRAULIC CYLINDER....................................................................... 953 Disassembly.......................................................................... 953 Assembly............................................................................. 956 WORK EQUIPMENT........................................................................... 960 Removal.............................................................................. 960 Installation......................................................................... 962 CAB...................................................................................... 963 Removal.............................................................................. 963 Installation......................................................................... 966 Cab Glass (Stuck Glass).............................................................. 967 Removal.......................................................................... 968 Installation..................................................................... 969 Front Window......................................................................... 979 Removal.......................................................................... 979 Installation..................................................................... 982 Floor Frame.......................................................................... 987 Removal.......................................................................... 987 Installation..................................................................... 991 ELECTRICAL SYSTEM........................................................................ 992 Air Conditioner Unit................................................................. 992 Removal.......................................................................... 992 Installation..................................................................... 995 KOMTRAX Communication Modem.......................................................... 996 Removal.......................................................................... 996 Installation..................................................................... 996 Monitor.............................................................................. 997 Removal.......................................................................... 997 Installation..................................................................... 998 Pump Controller...................................................................... 999 Removal.......................................................................... 999 Installation.....................................................................1000 Engine Controller....................................................................1002 Removal..........................................................................1002 Installation.....................................................................1002 60 AIR CONDITIONER...........................................................................1003 STRUCTURE AND FUNCTION...................................................................1006 Air Conditioner Component............................................................1006 Configuration and Function of Refrigerating cycle....................................1008 Outline of Refrigerating Cycle.......................................................1009 Air Conditioner Unit.................................................................1012 Functions of Major Components in the Air Conditioner Unit............................1014 Control Plate........................................................................1016 Compressor...........................................................................1019 Condenser and Receiver Drier.........................................................1020 TESTING AND ADJUSTING....................................................................1021 Caution About Refrigerant............................................................1021 Troubleshooting Procedure............................................................1022 Block Diagram........................................................................1023 Circuit Diagram and Arrangement of Connector Pins....................................1024 Detail of Air Conditioner Unit.......................................................1026 Part and Connector Locations.........................................................1028 Testing Air Leakage (Ducts)..........................................................1032 Testing with Self-diagnosis Function.................................................1034 Testing Temperature Control..........................................................1037 Testing Vent (Mode) Changeover.......................................................1040 Testing Recirc/Fresh Changeover......................................................1044 Testing Inner Sensor.................................................................1046 Testing Evaporator Temperature Sensor................................................1047 Testing Sunlight Sensor..............................................................1049 Testing (Dual) Pressure Switch for Refrigerant.......................................1050 Testing Relays.......................................................................1052 TROUBLESHOOTING..........................................................................1054 Troubleshooting Chart 1..............................................................1054 Troubleshooting Chart 2..............................................................1055 Troubleshooting for Electrical System (E mode).......................................1058 E-1 Power Supply System (Air Conditioner does not Operate).......................1059 E-2 Compressor System (Air is Not Cooled)........................................1063 E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)...............1066 E-4 Temperature Cannot be Controlled.............................................1070 E-5 Vent (Mode) Cannot be Changed Over...........................................1073 E-6 Recirc/Fresh Air Cannot be Changed Over......................................1076 Troubleshooting With Gauge Pressure..................................................1079 Connection of Service Tool...........................................................1082 Precautions for connecting air conditioner piping....................................1084 Handling of Compressor Oil...........................................................1085 Control of Compressor Oil........................................................1085 Adding of Compressor Oil.........................................................1085 Compressor Replacement...........................................................1086 Applying Compressor Oil for O-ring...............................................1086 Desiccant Replacement Procedure......................................................1087 90 DIAGRAMS AND DRAWINGS.....................................................................1089 HYDRAULIC SYSTEM.........................................................................1091 Hydraulic Circuit Diagram - PC350LC/HD-8.............................................1091 ELECTRICAL SYSTEM........................................................................1092 Electrical Circuit Diagram (1/5).....................................................1092 Electrical Circuit Diagram (2/5).....................................................1093 Electrical Circuit Diagram (3/5).....................................................1094 Electrical Circuit Diagram (4/5).....................................................1095 Electrical Circuit Diagram (5/5).....................................................1096 Connector Arrangement Diagram - PC350LC/HD-8.........................................1097
KOMATSU PC350LC-8, PC350HD-8 HYDRAULIC EXCAVATOR SHOP MANUAL CEBM007501 – PDF DOWNLOAD:
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