Komatsu PC550LC-8 Hydraulic Excavator Shop Manual SEN06368-00 PDF

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Komatsu PC550LC-8 Hydraulic Excavator Shop Manual SEN06368-00 – PDF DOWNLOAD

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Komatsu PC550LC-8 Hydraulic Excavator Shop Manual SEN06368-00 – PDF DOWNLOAD

Language : English
Pages : 1055
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC550LC-8 Hydraulic Excavator Shop Manual SEN06368-00 – PDF DOWNLOAD 

SERIAL NUMBERS 70458 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. 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.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu PC550LC-8 Hydraulic Excavator Shop Manual SEN06368-00 – PDF DOWNLOAD

SERIAL NUMBERS 70458 and up

COVER 1
00 Index and foreword 0
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines 34
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 0
Specification and technical data 57
Specification dimension drawings 58
Specifications 60
Weight table 62
Table of fuel, coolant and lubricants 64
10 Structure, function and maintenance standard 0
Engine and cooling system 67
Engine related parts 68
Radiator, oil cooler and aftercooler 69
Power train 71
Power train 72
Swing circle 73
Swing machinery 74
Final drive 76
Sprocket 79
Undercarriage and frame 83
Track frame, recoil spring 84
Idler 86
Carrier roller 88
Track roller 89
Track shoe 90
Hydraulic system, Part 1 97
Hydraulic equipment layout drawing 98
Hydraulic tank and filter 100
Hydraulic pump 102
Hydraulic system, Part 2 127
Control valve 128
CLSS 140
Functions and operation by valve 144
Merge-divider valve 159
Attachment circuit selector valve 184
Holding valve 186
Hydraulic system, Part 3 193
Valve control 194
PPC valve 196
Solenoid valve 212
PPC accumulator 214
Return oil filter 215
Center swivel joint 216
Travel motor 217
Parking brake 222
Brake valve 224
Set pressures varying mechanism 227
Swing motor 228
Hydraulic cylinder 236
Work equipment 239
Work equipment 240
Dimensions of components 242
Cab and its attachments 247
Air conditioner piping 248
Electrical system 251
Engine control 252
Electrical control system 263
Monitor system 288
Sensors 315
KOMTRAX terminal system 318
20 Standard value table 0
Standard service value table 321
Standard value table for engine 322
Standard value table for chassis related parts 323
30 Testing and adjusting 0
Testing and adjusting, Part 1 333
Tools for testing, adjusting and troubleshooting 335
Sketches of special tools 339
Testing engine speed 340
Testing air boost pressure 341
Testing exhaust temperature 342
Testing exhaust gas color 343
Adjusting valve clearance 344
Testing compression pressure 346
Testing blow-by pressure 348
Testing engine oil pressure 349
Testing EGR valve drive pressure 350
Handling fuel system parts 351
Releasing residual pressure from fuel system 351
Testing fuel pressure 352
Handling during cylinder cut-out operation 353
Handling during no injection cranking operation 353
Testing fuel return and leakage 354
Bleeding air from fuel circuit 357
Checking fuel circuit for leakage 359
Checking and adjusting fan belt and alternator belt 360
Checking and adjusting air conditioner compressor belt tension 361
Testing swing circle bearing clearance 362
Testing and adjusting track shoe tension 363
Testing and adjustment oil pressure in work equipment, swing, and travel circuits 364
Testing control circuit basic pressure 368
Checking and adjusting pump PC control circuit oil pressure 369
Checking and adjusting pump LS control circuit oil pressure 372
Testing solenoid valve output pressure 377
Testing PPC valve output pressure 381
Adjusting play of work equipment and swing PPC valves 383
Inspecting locations of hydraulic drift of work equipment 384
Releasing residual pressure from hydraulic circuit 386
Testing oil leakage amount 387
Bleeding air from various parts 391
Testing and adjusting, Part 2 395
Special functions of machine monitor 396
Testing and adjusting, Part 3 451
Handling voltage circuit of engine controller 452
Preparation work for troubleshooting of electrical system 453
Procedure for testing diodes 458
Pm Clinic service 459
Undercarriage troubleshooting report 466
40 Troubleshooting 0
Failure code table and fuse locations 469
Failure code table 470
Fuse locations 473
General Information on troubleshooting 479
Points to remember when troubleshooting 480
Sequence of events in troubleshooting 481
Check before troubleshooting 482
Classification and troubleshooting steps 483
Information in troubleshooting table 484
Possible problems and troubleshooting No 486
Connection table for connector pin numbers 488
T- branch box and T- branch adapter table 524
Troubleshooting by failure code, Part 1 529
Failure code [989L00] Engine Controller Lock Caution 1 531
Failure code [989M00] Engine Controller Lock Caution 2 532
Failure code [989N00] Engine Controller Lock Caution 3 533
Failure code [AA10NX] Air cleaner Clogging 534
Failure code [AB00KE] Charge Voltage Low 536
Failure code [B@BAZG] Eng Oil Press Low 538
Failure code [B@BAZK] Eng Oil Level Low 540
Failure code [B@BCNS] Eng Water Overheat 542
Failure code [B@BCZK] Eng Water Level Low 544
Failure code [B@HANS] Hydr Oil Overheat 546
Failure code [CA111] EMC Critical Internal Failure 547
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 549
Failure code [CA122] Chg Air Press Sensor High Error 550
Failure code [CA123] Chg Air Press Sensor Low Error 552
Failure code [CA131] Throttle Sensor High Error 554
Failure code [CA132] Throttle Sensor Low Error 556
Failure code [CA135] Eng Oil Press Sensor High Error 558
Failure code [CA141] Eng Oil Press Sensor Low Error 560
Failure code [CA144] Coolant Temp Sensor High Error 561
Failure code [CA145] Coolant Temp Sensor Low Error 563
Failure code [CA153] Chg Air Temp Sensor High Error 565
Failure code [CA154] Chg Air Temp Sensor Low Error 567
Failure code [CA187] Sens Supply 2 Volt Low Error 569
Failure code [CA221] Ambient Press Sens High Error 571
Failure code [CA222] Ambient Press Sens Low Error 573
Failure code [CA227] Sens Supply 2 Volt High Error 575
Failure code [CA234] Eng Overspeed 576
Failure code [CA238] Ne Speed Sens Supply Volt Error 577
Failure code [CA263] Fuel Temp Sensor High Error 578
Failure code [CA265] Fuel Temp Sensor Low Error 580
Failure code [CA271] IMV/PCV1 Short Error 581
Failure code [CA272] IMV/PCV1 Open Error 583
Failure code [CA273] PCV2 Short Error 585
Failure code [CA274] PCV2 Open Error 587
Failure code [CA322] Inj #1 Open/Short Error 589
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error 591
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error 593
Failure code [CA325] Inj #6 Open/Short Error 595
Failure code [CA331] Inj #2 Open/Short Error 597
Failure code [CA332] Inj #4 Open/Short Error 599
Troubleshooting by failure code, Part 2 603
Failure code [CA342] Calibration Code Incompatibility 605
Failure code [CA351] Injectors Drive Circuit Error 606
Failure code [CA352] Sens Supply 1 Volt Low Error 608
Failure code [CA386] Sens Supply 1 Volt High Error 610
Failure code [CA441] Battery Voltage Low Error 612
Failure code [CA442] Battery Voltage High Error 614
Failure code [CA449] Rail Press Very High Error 616
Failure code [CA451] Rail Press Sensor High Error 619
Failure code [CA452] Rail Press Sensor Low Error 621
Failure code [CA553] Rail Press High Error 623
Failure code [CA554] Rail Press Sensor In Range Error 624
Failure code [CA559] Rail Press Low Error 625
Failure code [CA689] Eng Ne Speed Sensor Error 629
Failure code [CA731] Eng Bkup Speed Sens Phase Error 631
Failure code [CA757] All Continuous Data Lost Error 632
Failure code [CA778] Eng Bkup Speed Sensor Error 634
Failure code [CA1228] EGR valve servo error 1 636
Failure code [CA1625] EGR valve servo error 2 637
Failure code [CA1633] KOMNET Datalink Timeout Error 638
Failure code [CA2185] Throt Sens Sup Volt High Error 640
Failure code [CA2186] Throt Sens Sup Volt Low Error 642
Failure code [CA2249] Rail Press Very Low Error 643
Failure code [CA2271] EGR valve lift sensor high error 644
Failure code [CA2272] EGR valve lift sensor low error 646
Failure code [CA2351] EGR valve solenoid operation short circuit 647
Failure code [CA2352] EGR valve solenoid operation disconnect 649
Failure code [CA2555] Grid Htr Relay Volt Low Error 650
Failure code [CA2556] Grid Htr Relay Volt High Error 652
Failure code [D110KB] Battery Relay Drive S/C 654
Failure code [D19JKZ] Personal Code Relay Abnormality 656
Failure code [D862KA] GPS Antenna Discon 658
Failure code [DA22KK] Pump Solenoid Power Low Error 659
Failure code [DA25KP] 5V sensor power supply output 1 abnormality 661
Failure code [DA29KQ] Model Selection Abnormality 664
Troubleshooting by failure code, Part 3 667
Failure code [DA2RMC] CAN Discon (Pump con detected) 669
Failure code [DAF8KB] Short circuit in camera power supply 671
Failure code [DAFGMC] GPS Module Error 673
Failure code [DAFRMC] CAN discon (Monitor detected) 674
Failure code [DGH2KB] Hyd Oil Sensor Short 676
Failure code [DHPAMA] F Pump Press Sensor Abnormality 677
Failure code [DHPBMA] R Pump Press Sensor Abnormality 679
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 681
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 683
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) 685
Failure code [DW43KA] Travel Speed Sol Open Circuit 686
Failure code [DW43KB] Travel Speed Sol Short Circuit 688
Failure code [DW45KA] Swing Brake Sol Open Circuit 690
Failure code [DW45KB] Swing Brake Sol Short Circuit 692
Failure code [DW91KA] Travel Junction Sol Open Circuit 694
Failure code [DW91KB] Travel Junction Sol Short Circuit 696
Failure code [DWA2KA] Attachment Sol Open Circuit 698
Failure code [DWA2KB] Attachment Sol Short Circuit 699
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 700
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 702
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 704
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 706
Failure code [DXA0KA] PC-EPC Sol Open Circuit 708
Failure code [DXA0KB] PC-EPC Sol Short Circuit 710
Failure code [DXE0KA] LS-EPC Sol Open Circuit 712
Failure code [DXE0KB] LS-EPC Sol Short Circuit 714
Failure code [DXE4KA] Service Current EPC Open Circuit 716
Failure code [DXE4KB] Service Current EPC Short Circuit 717
Failure code [DY20KA] Wiper Working Abnormality 718
Failure code [DY20MA] Wiper Parking Abnormality 720
Failure code [DY2CKA] Washer Drive Open Discon 722
Failure code [DY2CKB] Washer Drive Short Circuit 724
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 726
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 728
Troubleshooting of electrical system (E-mode) 731
Before carrying out troubleshooting of electrical system 734
Information contained in troubleshooting table 736
E-1 Engine does not start 737
E-2 Auto-decelerator does not operate 740
E-3 Automatic warming-up system does not operate 742
E-4 Preheater does not operate 744
E-5 All work equipment, swing, and travel mechanism do not move 746
E-6 Power maximizing function does not operate 748
E-7 Machine monitor does not display at all 750
E-8 Machine monitor does not display some items 752
E-9 Contents of display by machine monitor are different from applicable machine 752
E-10 Fuel level monitor was lighted in red while engine running 753
E-11 Engine coolant temperature gauge does not indicate normally 754
E-12 Hydraulic oil temperature gauge does not indicate normally 756
E-13 Fuel level gauge does not indicate normally 757
E-14 Swing lock monitor does not indicate normally 758
E-15 When monitor switch is operated, monitor displays nothing 760
E-16 Windshield wiper and window washer do not operate 762
E-17 Machine push-up function does not operate normally 766
E-18 Monitoring function fails to display “boom raise” normally 768
E-19 Monitoring function fails to display “boom lower” normally 770
E-20 Monitoring function fails to display “arm IN” normally 772
E-21 Monitoring function fails to display “arm OUT” normally 774
E-22 Monitoring function fails to display “bucket CURL” normally 776
E-23 Monitoring function fails to display “bucket DUMP” normally 778
E-24 Monitoring function fails to display “swing” normally 780
E-25 Monitoring function fails to display “travel” normally 782
E-26 Monitoring function fails to display “travel differential pressure” normally 784
E-27 Monitoring function fails to display “service” normally 786
E-28 KOMTRAX system does not operate normally 788
E-29 Air conditioner does not operate 790
E-30 Travel alarm does not sound or does not stop sounding 792
E-31 Horn does not sound 794
Troubleshooting of hydraulic and mechanical system (H-mode) 797
System chart for hydraulic and mechanical system 800
Information contained in troubleshooting table 802
H-1 All work equipment lack power, or travel and swing speeds are slow1 804
H-2 Engine speed sharply drops or engine stalls 806
H-3 No work equipment, swing or travel move 807
H-4 Abnormal noise is heard from around hydraulic pump 807
H-5 Auto-decelerator does not work 808
H-6 Fine control mode does not function or responds slow 808
H-7 Boom moves slowly or lacks power 809
H-8 Arm moves slowly or lacks power 810
H-9 Bucket moves slowly or lacks power 811
H-10 Work equipment does not move in its single operation 811
H-11 Work equipment has a bit too fast hydraulic drift 812
H-12 Work equipment has big time lag 814
H-13 Other work equipment moves when relieving single circuit 814
H-14 Power max switch does not operate 814
H-15 Machine push-up function does not operate 815
H-16 In compound operation of work equipment, speed of part loaded more is low 816
H-17 When machine swings and raises boom simultaneously, boom rising speed is low 816
H-18 When machine swings and travels simultaneously, travel speed lowers largely 816
H-19 Machine deviates during travel 817
H-20 Travel speed is low 818
H-21 Machine is not steered well or steering power is low 819
H-22 Travel speed does not change or travel speed is low or high 820
H-23 Travel system does not move (only one side) 821
H-24 Upper structure does not swing 822
H-25 Swing acceleration or swing speed is low 824
H-26 Upper structure overruns remarkably when it stops swinging 826
H-27 Large shock is made when upper structure stops swinging 827
H-28 Large sound is made when upper structure stops swinging 827
H-29 Hydraulic drift of swing is large 828
H-30 Attachment circuit is not changed 829
H-31 Oil flow in attachment circuit cannot be controlled 829
Troubleshooting of engine (S-mode) 831
Method of using troubleshooting chart 833
S-1 Starting performance is poor 836
S-2 Engine does not start 838
S-3 Engine does not pick up smoothly 842
S-4 Engine stops during operations 843
S-5 Engine does not rotate smoothly 844
S-6 Engine lacks output (or lacks power) 845
S-7 Exhaust smoke is black (incomplete combustion) 846
S-8 Oil consumption is excessive (or exhaust smoke is blue) 847
S-9 Oil becomes contaminated quickly 848
S-10 Fuel consumption is excessive 849
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 850
S-12 Oil pressure drops 851
S-13 Oil level rises (Entry of coolant or fuel) 852
S-14 Coolant temperature becomes too high (overheating) 854
S-15 Abnormal noise is made 855
S-16 Vibration is excessive 856
50 Disassembly and assembly 0
General information on disassembly and assembly 859
How to read this manual 860
Coating materials list 862
Special tool list 865
Sketches of special tools 872
Engine and cooling system 879
Removal and installation of fuel supply pump assembly 880
Removal and installation of fuel injector assembly 884
Removal and installation of engine front seal 890
Removal and installation of engine rear seal 893
Removal and installation of cylinder head assembly 898
Removal and installation of radiator assembly 907
Removal and installation of hydraulic oil cooler assembly 909
Removal and installation of aftercooler assembly 911
Removal and installation of engine and hydraulic oil pump assembly 912
Power train 921
Disassembly and assembly of final drive assembly 922
Removal and installation of swing motor and swing machinery assembly 932
Disassembly and assembly of swing motor and swing machinery assembly 933
Removal and installation of swing circle assembly 940
Undercarriage and frame 943
Removal and installation of track shoe assembly 944
Disassembly and assembly of 1 link in field 946
Removal and installation of idler, recoil spring assembly 950
Disassembly and assembly of idler assembly 951
Disassembly and assembly of recoil spring assembly 954
Removal and installation of track roller assembly 956
Disassembly and assembly of track roller assembly 957
Removal and installation of carrier roller assembly 960
Disassembly and assembly of carrier roller assembly 961
Removal and installation of revolving frame assembly 964
Removal and installation of counterweight assembly 964
Hydraulic system 971
Removal and installation of center swivel joint assembly 972
Disassembly and assembly of center swivel joint assembly 974
Removal and installation of hydraulic tank assembly 975
Removal and installation of control valve assembly 977
Disassembly and assembly of control valve assembly 980
Removal and installation of hydraulic pump assembly 981
Removal and installation of oil seal in hydraulic pump input shaft 984
Disassembly and assembly of work equipment PPC valve assembly 985
Disassembly and assembly of travel PPC valve assembly 987
Disassembly and assembly of hydraulic cylinder assembly 990
Work equipment 997
Removal and installation of work equipment assembly 998
Cab and its attachments 1003
Removal and installation of operator cab assembly 1004
Removal and installation of operator cab glass (stuck glass) 1007
Removal and installation of front window assembly 1017
Removal and installation of floor frame assembly 1024
Electrical system 1029
Removal and installation of air conditioner unit assembly 1030
Removal and installation of KOMTRAX communication modem assembly 1033
Removal and installation of monitor assembly 1034
Removal and installation of pump controller assembly 1036
Removal and installation of engine controller 1038
90 Diagrams and drawings 0
Hydraulic diagrams and drawings 1041
Hydraulic circuit diagram 1043
Electrical diagrams and drawings 1046
Electrical circuit diagram 1048
Connector list and stereogram 1053

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