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Komatsu PC350LC-8 PC350LCD-8 PC350NLC-8 PC350NLCD-8 Hydraulic Excavator Service Repair Manual – PDF Download
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Komatsu PC350LC-8 PC350LCD-8 PC350NLC-8 PC350NLCD-8 Hydraulic Excavator Service Repair Manual
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Description
Komatsu PC350LC-8 PC350LCD-8 PC350NLC-8 PC350NLCD-8 Hydraulic Excavator Service Repair Manual
Description:
Komatsu PC350LC-8 PC350LCD-8 PC350NLC-8 PC350NLCD-8 Hydraulic Excavator Service Repair Manual
- 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. Always wear safety glasses when hitting parts with a hammer. 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.
Table of Contents:
Komatsu PC350LC-8 PC350LCD-8 PC350NLC-8 PC350NLCD-8 Hydraulic Excavator Service Repair Manual
00 Index and foreword........................................................................ 3 Index.................................................................................... 3 Composition of shop manual........................................................... 4 Table of contents.................................................................... 6 00 Index and foreword........................................................................ 15 Foreword and general information......................................................... 15 Safety notice........................................................................ 16 How to read the shop manual.......................................................... 21 Explanation of terms for maintenance standard........................................ 23 Handling electric equipment and hydraulic component.................................. 25 How to read electric wire code....................................................... 37 Precautions when carrying out operation.............................................. 40 Method of disassembling and connecting push-pull type coupler........................ 43 Standard tightening torque table..................................................... 46 Conversion table..................................................................... 50 01 Specification............................................................................. 57 Specification and technical data......................................................... 57 Specification dimension drawings..................................................... 58 Specifications....................................................................... 60 Weight table......................................................................... 63 Table of fuel, coolant and lubricants................................................ 64 10 Structure, function and maintenance standard.............................................. 67 Engine and cooling system................................................................ 67 Engine and cooling system............................................................ 68 Engine related parts............................................................. 68 Radiator, oil cooler and aftercooler............................................. 69 Diesel Particulate Filter............................................................ 70 Diesel Particulate Filter - Component Parts...................................... 71 System Description............................................................... 72 Regeneration..................................................................... 72 10 Structure, function and maintenance standard.............................................. 75 Power train.............................................................................. 75 Power train.......................................................................... 76 Final drive.......................................................................... 78 Sprocket............................................................................. 80 Swing machinery...................................................................... 82 Swing circle......................................................................... 84 10 Structure, function and maintenance standard.............................................. 87 Undercarriage and frame.................................................................. 87 Track frame and recoil spring........................................................ 88 Idler................................................................................ 90 Carrier roller....................................................................... 92 Track roller......................................................................... 93 Track shoe........................................................................... 94 10 Structure, function and maintenance standard.............................................. 99 Hydraulic system, Part 1................................................................. 99 Hydraulic equipment layout drawing................................................... 100 Hydraulic tank and filter............................................................ 102 Hydraulic pump....................................................................... 104 10 Structure, function and maintenance standard.............................................. 129 Hydraulic system, Part 2................................................................. 129 Control valve........................................................................ 130 CLSS................................................................................. 142 Functions and operation by valve..................................................... 146 Merge-divider valve.................................................................. 161 Attachment circuit selector valve.................................................... 186 Hydraulic drift prevention valve..................................................... 188 10 Structure, function and maintenance standard.............................................. 195 Hydraulic system, Part 3................................................................. 195 Valve control........................................................................ 196 PPC valve............................................................................ 198 Solenoid valve....................................................................... 220 PPC accumulator...................................................................... 222 Return oil filter.................................................................... 223 Centre swivel joint.................................................................. 224 Travel motor......................................................................... 225 Swing motor.......................................................................... 237 Hydraulic cylinder................................................................... 246 10 Structure, function and maintenance standard.............................................. 249 Work equipment........................................................................... 249 Work equipment....................................................................... 250 Work equipment................................................................... 250 Dimensions of components......................................................... 252 10 Structure, function and maintenance standard.............................................. 257 Cab and its attachments.................................................................. 257 Air conditioner piping............................................................... 258 10 Structure, function and maintenance standard.............................................. 261 Electrical system........................................................................ 261 Engine control....................................................................... 262 Electronic control system............................................................ 271 Monitor system....................................................................... 297 Sensor............................................................................... 324 KOMTRAX terminal system.............................................................. 327 10 Structure, function and maintenance standard.............................................. 331 Auto Grease system....................................................................... 331 Outline of Auto Grease System........................................................ 332 20 Standard value table...................................................................... 347 Standard service value table............................................................. 347 Standard value table for engine related parts........................................ 348 Standard value table for chassis related parts....................................... 349 30 Testing and adjusting..................................................................... 361 Testing and adjusting, Part 1............................................................ 361 Tools for testing, adjusting and troubleshooting..................................... 363 Measuring engine speed............................................................... 367 Measuring air boost pressure......................................................... 368 Measuring exhaust gas color.......................................................... 369 Adjusting valve clearance............................................................ 371 Measuring compression pressure....................................................... 373 Measuring blow-by pressure........................................................... 377 Measuring engine oil pressure........................................................ 378 Measuring fuel pressure.............................................................. 379 Handling during cylinder cut-out operation........................................... 383 Handling during no injection cranking operation...................................... 383 Measuring fuel return rate and leakage............................................... 384 Bleeding air from fuel circuit....................................................... 386 Checking fuel circuit for leakage.................................................... 387 Testing and adjusting air compressor belt tension.................................... 388 Measuring clearance in swing circle bearings......................................... 389 Testing and adjusting track shoe tension............................................. 390 Testing and adjusting oil pressure in work equipment, swing and travel circuit....... 391 Testing and adjusting control circuit oil pressure................................... 395 Testing and adjusting pump PC control circuit oil pressure........................... 396 Testing and adjusting pump LS control circuit oil pressure........................... 399 Measuring solenoid valve output pressure............................................. 404 Measuring PPC valve output pressure.................................................. 408 Adjusting play of work equipment and swing PPC valves................................ 409 Inspecting locations of hydraulic drift of work equipment............................ 410 Releasing remaining pressure in hydraulic circuit.................................... 412 Measuring oil leakage amount......................................................... 412 Bleeding air from various parts...................................................... 415 Diode inspection procedures.......................................................... 417 30 Testing and adjusting..................................................................... 419 Testing and adjusting, Part 2............................................................ 419 Special functions of machine monitor................................................. 420 30 Testing and adjusting..................................................................... 477 Testing and adjusting, Part 3............................................................ 477 Handling voltage circuit of engine controller........................................ 478 Preparation work for troubleshooting of electrical system............................ 479 Procedure for testing diodes......................................................... 483 Pm clinic service.................................................................... 484 40 Troubleshooting........................................................................... 491 Failure code table and fuse locations.................................................... 491 Failure codes table.................................................................. 492 Fuse locations....................................................................... 495 40 Troubleshooting........................................................................... 501 General information on troubleshooting................................................... 501 Points to remember when troubleshooting.............................................. 502 Sequence of events in troubleshooting................................................ 503 Checks before troubleshooting........................................................ 504 Classification and troubleshooting steps............................................. 505 Information in troubleshooting table................................................. 506 Connection table for connector pin numbers........................................... 511 T-adapter box and T-adapter table.................................................... 543 40 Troubleshooting........................................................................... 549 Troubleshooting by failure code (Display of code), Part 1................................ 549 Failure code [A000N1] Eng. Hi Out of Std............................................. 551 Failure code [AA10NX] Air cleaner Clogging........................................... 552 Failure code [AB00KE] Charge Voltage Low............................................. 554 Failure code [B@BAZG] Eng Oil Press. Low............................................. 556 Failure code [B@BAZK] Eng Oil Level Low.............................................. 558 Failure code [B@BCNS] Eng. Water Overheat............................................ 560 Failure code [B@BCZK] Eng Water Level Low............................................ 562 Failure code [B@HANS] Hydr Oil Overheat.............................................. 564 Failure code [CA111] EMC Critical Internal Failure................................... 565 Failure code [CA115] Eng Ne and Bkup Speed Sens Error................................ 565 Failure code [CA122] Chg Air Press Sensor High Error................................. 566 Failure code [CA123] Chg Air Press Sensor Low Error.................................. 568 Failure code [CA131] Throttle Sensor High Error...................................... 570 Failure code [CA132] Throttle Sensor Low Error....................................... 572 Failure code [CA144] Coolant Temp Sens High Error.................................... 574 Failure code [CA145] Coolant Temp Sens Low Error..................................... 576 Failure code [CA153] Chg Air Temp Sensor High Error.................................. 578 Failure code [CA154] Chg Air Temp Sensor Low Error................................... 580 Failure code [CA187] Sens Supply 2 Volt Low Error.................................... 582 Failure code [CA221] Ambient Press Sens High Error................................... 584 Failure code [CA222] Ambient Press Sens Low Error.................................... 586 Failure code [CA227] Sens Supply 2 Volt High Error................................... 588 Failure code [CA234] Eng Overspeed................................................... 589 Failure code [CA238] Ne Speed Sens Supply Volt Error................................. 590 Failure code [CA271] IMV/PCV1 Short Error............................................ 591 Failure code [CA272] IMV/PCV1 Open Error............................................. 592 Failure code [CA322] Inj #1 Open/Short Error......................................... 594 Failure code [CA323] Inj #5 Open/Short Error......................................... 596 Failure code [CA324] Inj #3 Open/Short Error......................................... 598 Failure code [CA325] Inj #6 Open/Short Error......................................... 600 Failure code [CA331] Inj #2 Open/Short Error......................................... 602 Failure code [CA332] Inj #4 Open/Short Error......................................... 604 40 Troubleshooting........................................................................... 607 Troubleshooting by failure code (Display of code), Part 2................................ 607 Failure code [CA342] Calibration Code Incompatibility................................ 609 Failure code [CA351] Injectors Drive Circuit Error................................... 610 Failure code [CA352] Sens Supply 1 Volt Low Error.................................... 612 Failure code [CA386] Sens Supply 1 Volt High Error................................... 614 Failure code [CA428] Water in Fuel Sensor High Error................................. 616 Failure code [CA429] Water in Fuel Sensor Low Error.................................. 618 Failure code [CA441] Battery Voltage Low Error....................................... 620 Failure code [CA442] Battery Voltage High Error...................................... 622 Failure code [CA449] Rail Press Very High Error...................................... 624 Failure code [CA451] Rail Press Sensor High Error.................................... 628 Failure code [CA452] Rail Press Sensor Low Error..................................... 630 Failure code [CA553] Rail Press High Error........................................... 632 Failure code [CA559] Rail Press Low Error............................................ 633 Failure code [CA689] Eng Ne Speed Sensor Error....................................... 635 Failure code [CA731] Eng Bkup Speed Sens Phase Error................................. 637 Failure code [CA757] All Persistent Data Lost Error.................................. 638 Failure code [CA778] Eng Bkup Speed Sensor Error..................................... 640 Failure code [CA1633] KOMNET Datalink Timeout Error.................................. 642 Failure code [CA2185] Throt Sens Sup Volt High Error................................. 644 Failure code [CA2186] Throt Sens Sup Volt Low Error.................................. 645 Failure code [CA2249] Rail Press Very Low Error...................................... 646 Failure code [CA2265] Electric Lift Pump High Error.................................. 648 Failure code [CA2266] Electric Lift Pump Low Error................................... 650 Failure code [CA2555] Grid Htr Relay Volt High Error................................. 652 Failure code [CA2556] Grid Htr Relay Volt Low Error.................................. 654 Failure code [D110KB] Battery Relay Drive S/C........................................ 656 Failure code [DA25KP] 5V sensor 1 power abnormality.................................. 658 Failure code [DA2RMC] Pump Comm. Abnormality......................................... 662 Failure code [DA2SKQ] Model Selection Abnormality.................................... 664 40 Troubleshooting........................................................................... 667 Troubleshooting by failure code (Display of code), Part 3................................ 667 Failure code [DAFRMC] CAN discon (Monitor detected).................................. 670 Failure code [DHPAMA] F Pump Press Sensor Abnormality................................ 672 Failure code [DHPBMA] R Pump Press Sensor Abnormality................................ 674 Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality.................................. 676 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality....................... 678 Failure code [DW43KA] Travel Speed Sol. Disc......................................... 680 Failure code [DW43KB] Travel Speed Sol. S/C.......................................... 682 Failure code [DW45KA] Swing Brake Sol. Disc.......................................... 684 Failure code [DW45KB] Swing Brake Sol. S/C........................................... 688 Failure code [DW91KA] Travel Junction Sol. Disc...................................... 690 Failure code [DW91KB] Travel Junction Sol. S/C....................................... 692 Failure code [DWJ0KA] Merge-divider Sol. Disc........................................ 694 Failure code [DWJ0KB] Merge-divider Sol. S/C......................................... 696 Failure code [DWK0KA] 2-stage Relief Sol. Disc....................................... 698 Failure code [DWK0KB] 2-stage Relief Sol. S/C........................................ 700 Failure code [DXA0KA] PC-EPC Sol. Disc............................................... 702 Failure code [DXA0KB] PC-EPC Sol. S/C................................................ 704 Failure code [DXE0KA] LS-EPC Sol. Disc............................................... 706 Failure code [DXE0KB] LS-EPC Sol. S/C................................................ 708 Failure code [DXE4KA] Service Current EPC Disc....................................... 710 Failure code [DXE4KB] Service Current EPC S/C........................................ 711 Failure code [DY20KA] Wiper Working Abnormality...................................... 712 Failure code [DY20MA] Wiper Parking Abnormality...................................... 714 Failure code [DY2CKB] Washer Drive Short............................................. 716 Failure code [DY2DKB] Wiper Drive (For) Short........................................ 718 Failure code [DY2EKB] Wiper Drive (Rev) Short........................................ 720 40 Troubleshooting........................................................................... 723 Troubleshooting of electrical system (E-mode)............................................ 723 Before carrying out troubleshooting of electrical system............................. 726 Information contained in troubleshooting table....................................... 728 E-1 Engine does not start............................................................ 729 E-2 Auto-decelerator does not operate................................................ 732 E-3 Automatic warming-up system does not operate..................................... 734 E-4 Preheater does not operate....................................................... 736 E-5 All work equipment, swing, and travel mechanism do not move...................... 738 E-6 Power maximizing function does not operate....................................... 740 E-7 Machine monitor does not display at all.......................................... 742 E-8 Machine monitor does not display some items...................................... 744 E-9 Contents of display by machine monitor are different from applicable machine..... 744 E-10 Fuel level monitor was lighted in red while engine running...................... 745 E-11 Engine coolant temperature gauge does not indicate normally..................... 746 E-12 Hydraulic oil temperature gauge does not indicate normally...................... 748 E-13 Fuel level gauge does not indicate normally..................................... 749 E-14 Swing lock monitor does not indicate normally................................... 750 E-15 When monitor switch is operated, monitor displays nothing....................... 752 E-16 Windshield wiper and window washer do not operate............................... 754 E-17 Machine push-up function does not operate normally.............................. 758 E-18 Monitoring function fails to display “boom raise” normally...................... 760 E-19 Monitoring function fails to display “boom lower” normally...................... 762 E-20 Monitoring function fails to display “arm IN” normally.......................... 764 E-21 Monitoring function fails to display “arm OUT” normally......................... 766 E-22 Monitoring function fails to display “bucket CURL” normally..................... 768 E-23 Monitoring function fails to display “bucket DUMP” normally..................... 770 E-24 Monitoring function fails to display “swing” normally........................... 772 E-25 Monitoring function fails to display “travel” normally.......................... 774 E-26 Monitoring function fails to display “travel differential pressure” normally.... 776 E-27 Monitoring function fails to display “service” normally......................... 778 E-28 KOMTRAX system does not operate normally........................................ 780 E-29 Air conditioner does not operate................................................ 782 E-30 Travel alarm does not sound or does not stop sounding........................... 784 E-31 Horn does not sound............................................................. 786 40 Troubleshooting........................................................................... 789 Troubleshooting of hydraulic and mechanical system (H-mode).............................. 789 System chart for hydraulic and mechanical system..................................... 792 Information contained in troubleshooting table....................................... 794 H-1 All work equipment lack power, or travel and swing speeds are slow............... 796 H-2 Engine speed sharply drops or engine stalls...................................... 798 H-3 No work equipment, swing or travel move.......................................... 799 H-4 Abnormal noise is heard from around hydraulic pump............................... 799 H-5 Auto-decelerator does not work................................................... 800 H-6 Fine control mode does not function or responds slow............................. 800 H-7 Boom moves slowly or lacks power................................................. 801 H-8 Arm moves slowly or lacks power.................................................. 802 H-9 Bucket moves slowly or lacks power............................................... 803 H-10 Work equipment does not move in its single operation............................ 803 H-11 Work equipment has a bit too fast hydraulic drift............................... 804 H-12 Work equipment has big time lag................................................. 806 H-13 Other work equipment moves when relieving single circuit........................ 806 H-14 Power max. switch does not operate.............................................. 807 H-15 In compound operation, work equipment with larger load moves slowly............. 807 H-16 In swing + boom RAISE operation, boom moves slowly.............................. 808 H-17 In swing + travel operation, travel speed drops sharply......................... 808 H-18 Machine swerves in travel....................................................... 809 H-19 Machine travels slowly.......................................................... 810 H-20 Machine cannot be easily steered or lacks power................................. 811 H-21 Travel speed does not shift, or it is too slow or fast.......................... 812 H-22 Track shoe does not turn (on one side only)..................................... 813 H-23 Machine does not swing.......................................................... 814 H-24 Swing acceleration is poor, or swing speed is slow.............................. 816 H-25 Excessive overrun when stopping swing........................................... 818 H-26 There is big shock when stopping swing.......................................... 819 H-27 Large sound is made when upper structure stops swinging......................... 819 H-28 Swing hydraulic drift is too big................................................ 820 40 Troubleshooting........................................................................... 823 Troubleshooting of engine (S-mode)....................................................... 823 Method of using troubleshooting chart................................................ 825 S-1 Starting performance is poor..................................................... 828 S-2 Engine does not start............................................................ 829 S-3 Engine does not pick up smoothly................................................. 832 S-4 Engine stops during operations................................................... 833 S-5 Engine does not rotate smoothly.................................................. 834 S-6 Engine lacks output (or lacks power)............................................. 835 S-7 Exhaust smoke is black (incomplete combustion)................................... 836 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................... 837 S-9 Oil becomes contaminated quickly................................................. 838 S-10 Fuel consumption is excessive................................................... 839 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)........... 840 S-12 Oil pressure drops.............................................................. 841 S-13 Oil level rises (Entry of coolant or fuel)...................................... 842 S-14 Coolant temperature becomes too high (overheating).............................. 843 S-15 Abnormal noise is made.......................................................... 844 S-16 Vibration is excessive.......................................................... 845 S-17 Diesel Particulate Filter System................................................ 846 40 Troubleshooting........................................................................... 849 Troubleshooting of Auto Grease system.................................................... 849 50 Disassembly and assembly.................................................................. 857 General information on disassembly and assembly.......................................... 857 How to read this manual.............................................................. 858 Coating materials list............................................................... 860 Special tools list................................................................... 863 Sketches of special tools............................................................ 867 50 Disassembly and assembly.................................................................. 871 Engine and cooling system................................................................ 871 Removal and installation of fuel supply pump assembly................................ 872 Removal and installation of engine front seal........................................ 875 Removal and installation of engine rear seal......................................... 877 Removal and installation of cylinder head assembly................................... 882 Removal and installation of radiator assembly........................................ 894 Removal and installation of hydraulic oil cooler assembly............................ 896 Removal and installation of aftercooler assembly..................................... 898 Removal and installation of engine and hydraulic pump assembly....................... 899 50 Disassembly and assembly.................................................................. 905 Power train.............................................................................. 905 Removal and installation of final drive assembly..................................... 906 Disassembly and assembly of final drive assembly..................................... 907 Removal and installation of swing motor and swing machinery assembly................. 915 Disassembly and assembly of swing motor and swing machinery assembly................. 916 Removal and installation of swing circle assembly.................................... 923 50 Disassembly and assembly.................................................................. 925 Undercarriage and frame.................................................................. 925 Disassembly and assembly of carrier roller........................................... 926 Disassembly and assembly of track roller assembly.................................... 927 Disassembly and assembly of idler assembly........................................... 928 Disassembly and assembly of recoil spring............................................ 931 Removal and installation of sprocket................................................. 933 Expansion and installation of track shoe assembly.................................... 934 Removal and installation of revolving frame assembly................................. 935 Removal and installation of counterweight assembly................................... 937 50 Disassembly and assembly.................................................................. 939 Hydraulic system......................................................................... 939 Removal and installation of centre swivel joint assembly............................. 940 Disassembly and assembly of centre swivel joint assembly............................. 942 Removal and installation of hydraulic tank assembly.................................. 943 Removal and installation of control valve assembly................................... 945 Disassembly and assembly of control valve assembly................................... 948 Removal and installation of hydraulic pump assembly.................................. 950 Removal and installation of oil seal in hydraulic pump input shaft................... 952 Disassembly and assembly of work equipment PPC valve assembly........................ 953 Disassembly and assembly of travel PPC valve assembly................................ 954 Disassembly and assembly of hydraulic cylinder assembly.............................. 955 50 Disassembly and assembly.................................................................. 961 Work equipment........................................................................... 961 Removal and installation of work equipment assembly.................................. 962 50 Disassembly and assembly.................................................................. 967 Cab and its attachments.................................................................. 967 Removal and installation of operator's cab assembly.................................. 968 Removal and installation of operator cab glass (stuck glass)......................... 971 Removal and installation of front window assembly.................................... 981 Removal and installation of floor frame assembly..................................... 988 50 Disassembly and assembly.................................................................. 993 Electrical system........................................................................ 993 Removal and installation of air conditioner unit assembly............................ 994 Removal and installation of KOMTRAX communication modem assembly..................... 997 Removal and installation of monitor assembly......................................... 998 Removal and installation of pump controller assembly.................................1000 Removal and installation of engine controller........................................1002 90 Diagrams and drawings.....................................................................1005 Hydraulic diagrams and drawings..........................................................1005 Hydraulic circuit diagram 1/2........................................................ 0 Hydraulic circuit diagram 2/2........................................................ 0 90 Diagrams and drawings.....................................................................1013 Electrical diagrams and drawings.........................................................1013 Connector arrangement diagram........................................................ 0 Electrical circuit diagrams K50001-K50649 (1/5)...................................... 0 Electrical circuit diagrams K50001-K50649 (2/5)...................................... 0 Electrical circuit diagrams K50001-K50649 (3/5)...................................... 0 Electrical circuit diagrams K50001-K50649 (4/5)...................................... 0 Electrical circuit diagrams K50001-K50649 (5/5)...................................... 0 Electrical circuit diagrams K50650-Up (1/5).......................................... 0 Electrical circuit diagrams K50650-Up (2/5).......................................... 0 Electrical circuit diagrams K50650-Up (3/5).......................................... 0 Electrical circuit diagrams K50650-Up (4/5).......................................... 0 Electrical circuit diagrams K50650-Up (5/5).......................................... 0
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KOMATSU PC350LC-8 PC350LCD-8 PC350NLC-8 PC350NLCD-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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