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Komatsu PC340LC-7, PC340NLC-7 Hydraulic Excavator Shop Manual - PDF DOWNLOAD
Komatsu PC340LC-7, PC340NLC-7 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC340LC-7, PC340NLC-7 Hydraulic Excavator Shop Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEN00262-00
Total Pages : 910
DESCRIPTION:
Komatsu PC340LC-7, PC340NLC-7 Hydraulic Excavator Shop Manual
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)
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC340LC-7, PC340NLC-7 Hydraulic Excavator Shop Manual
00 Index and foreword............................................................................ 3 Index........................................................................................ 3 Organization list of the shop manual..................................................... 4 Table of contents........................................................................ 6 00 Index and foreword............................................................................ 15 Foreword and general information............................................................. 15 Foreword and general information......................................................... 16 Safety notice........................................................................ 16 How to read the shop manual.......................................................... 20 Explanation of terms for maintenance standard........................................ 22 Handling electric equipment and hydraulic component.................................. 24 How to read electric wire code....................................................... 32 Method of disassembling and connecting push-pull type coupler........................ 35 Standard tightening torque table..................................................... 38 Conversion table..................................................................... 42 01 Specification................................................................................. 49 Specification and technical data............................................................. 49 Specification and technical data......................................................... 50 Specification dimension drawings..................................................... 50 Specifications....................................................................... 52 Weight table......................................................................... 55 Table of fuel, coolant and lubricants................................................ 56 10 Structure, function and maintenance standard.................................................. 59 Engine and cooling system.................................................................... 59 Engine and cooling system................................................................ 60 Engine related parts................................................................. 60 Radiator, oil cooler and aftercooler................................................. 61 10 Structure, function and maintenance standard.................................................. 63 Power train.................................................................................. 63 Power train.............................................................................. 64 Power train.......................................................................... 64 Final drive.......................................................................... 66 Sprocket............................................................................. 68 Swing machinery...................................................................... 70 Swing circle......................................................................... 72 10 Structure, function and maintenance standard.................................................. 75 Undercarriage and frame...................................................................... 75 Undercarriage and frame.................................................................. 76 Track frame and recoil spring........................................................ 76 Idler................................................................................ 78 Carrier roller....................................................................... 80 Track roller......................................................................... 81 Track shoe........................................................................... 82 10 Structure, function and maintenance standard.................................................. 87 Hydraulic system, Part 1..................................................................... 87 Hydraulic system, Part 1................................................................. 88 Hydraulic equipment layout drawing................................................... 88 Hydraulic tank and filter............................................................ 90 Hydraulic pump....................................................................... 92 10 Structure, function and maintenance standard..................................................117 Hydraulic system, Part 2.....................................................................117 Hydraulic system, Part 2.................................................................118 Control valve........................................................................118 CLSS.................................................................................130 Functions and operation by valve.....................................................134 Merge-divider valve..................................................................149 Attachment circuit selector valve....................................................168 Hydraulic drift prevention valve.....................................................170 10 Structure, function and maintenance standard..................................................177 Hydraulic system, Part 3.....................................................................177 Hydraulic system, Part 3.................................................................178 Valve control........................................................................178 PPC valve............................................................................180 Solenoid valve.......................................................................196 PPC accumulator......................................................................198 Return oil filter....................................................................199 Center swivel joint..................................................................200 Travel motor.........................................................................201 Swing motor..........................................................................213 Hydraulic cylinder...................................................................222 10 Structure, function and maintenance standard..................................................225 Work equipment...............................................................................225 Work equipment...........................................................................226 Work equipment.......................................................................226 Dimensions of components.............................................................228 10 Structure, function and maintenance standard..................................................233 Cab and its attachments......................................................................233 Cab and its attachments..................................................................234 Air conditioner piping...............................................................234 10 Structure, function and maintenance standard..................................................237 Electrical system............................................................................237 Electrical system........................................................................238 Engine control.......................................................................238 Electronic control system............................................................247 Monitor system.......................................................................274 Sensor...............................................................................292 KOMTRAX terminal system..............................................................295 20 Standard value table..........................................................................299 Standard service value table.................................................................299 Standard service value table.............................................................300 Standard value table for engine related parts........................................300 Standard value table for chassis related parts.......................................301 30 Testing and adjusting.........................................................................313 Testing and adjusting, Part 1................................................................313 Testing and adjusting, Part 1............................................................315 Tools for testing, adjusting and troubleshooting.....................................315 Measuring engine speed...............................................................317 Measuring air boost pressure.........................................................318 Measuring exhaust gas color..........................................................319 Adjusting valve clearance............................................................321 Measuring compression pressure.......................................................323 Measuring blow-by pressure...........................................................327 Measuring engine oil pressure........................................................328 Measuring fuel pressure..............................................................329 Handling during cylinder cut-out operation...........................................333 Handling during no injection cranking operation......................................333 Measuring fuel return rate and leakage...............................................334 Bleeding air from fuel circuit.......................................................336 Checking fuel circuit for leakage....................................................337 Checking and adjusting air compressor belt tension...................................338 Measuring clearance in swing circle bearings.........................................339 Checking and adjusting track shoe tension............................................340 Checking and adjusting oil pressure in work equipment, swing and travel circuit......341 Checking and adjusting control circuit oil pressure..................................345 Checking and adjusting pump PC control circuit oil pressure..........................346 Checking and adjusting pump LS control circuit oil pressure..........................349 Measuring solenoid valve output pressure.............................................354 Measuring PPC valve output pressure..................................................358 Adjusting play of work equipment and swing PPC valves................................359 Inspecting locations of hydraulic drift of work equipment............................360 Releasing remaining pressure in hydraulic circuit....................................362 Measuring oil leakage amount.........................................................362 Bleeding air from various parts......................................................365 Diode inspection procedures..........................................................367 30 Testing and adjusting.........................................................................369 Testing and adjusting, Part 2................................................................369 Testing and adjusting, Part 2............................................................370 Special functions of machine monitor.................................................370 Handling voltage circuit of engine controller........................................397 Procedure for turning on KOMTRAX terminal............................................398 KOMTRAX terminal lamp indications....................................................401 Preparation work for troubleshooting of electrical system............................404 Pm clinic service....................................................................407 40 Troubleshooting...............................................................................413 General information on troubleshooting.......................................................413 Information related to troubleshooting...................................................414 Points to remember when troubleshooting..............................................414 Sequence of events in troubleshooting................................................415 Checks before troubleshooting........................................................416 Classification and troubleshooting steps.............................................417 Connection table for connector pin numbers...........................................421 T-boxes and T-adapters table.........................................................444 40 Troubleshooting...............................................................................449 Troubleshooting by failure code (Display of code), Part 1....................................449 Troubleshooting by failure code (Display of code), Part 1................................451 Failure codes table..................................................................451 Before carrying out troubleshooting when failure code is displayed...................454 Information in troubleshooting table.................................................458 Failure code [A000N1] Eng. Hi Out of Std.............................................460 Failure code [AA10NX] Air cleaner Clogging...........................................461 Failure code [AB00KE] Charge Voltage Low.............................................462 Failure code [B@BAZG] Eng Oil Press. Low.............................................464 Failure code [B@BAZK] Eng Oil Level Low..............................................466 Failure code [B@BCNS] Eng. Water Overheat............................................468 Failure code [B@BCZK] Eng Water Level Low............................................470 Failure code [B@HANS] Hydr Oil Overheat..............................................471 Failure code [CA111] EMC Critical Internal Failure...................................472 Failure code [CA115] Eng Ne and Bkup Speed Sens Error................................472 Failure code [CA122] Chg Air Press Sensor High Error.................................474 Failure code [CA123] Chg Air Press Sensor Low Error..................................476 Failure code [CA131] Throttle Sensor High Error......................................478 Failure code [CA132] Throttle Sensor Low Error.......................................480 Failure code [CA144] Coolant Temp Sens High Error....................................482 Failure code [CA145] Coolant Temp Sens Low Error.....................................484 Failure code [CA153] Chg Air Temp Sensor High Error..................................486 Failure code [CA154] Chg Air Temp Sensor Low Error...................................488 Failure code [CA187] Sens Supply 2 Volt Low Error....................................490 Failure code [CA221] Ambient Press Sens High Error...................................492 Failure code [CA222] Ambient Press Sens Low Error....................................494 Failure code [CA227] Sens Supply 2 Volt High Error...................................496 Failure code [CA234] Eng Overspeed...................................................497 Failure code [CA238] Ne Speed Sens Supply Volt Error.................................498 Failure code [CA271] IMV/PCV1 Short Error............................................499 Failure code [CA272] IMV/PCV1 Open Error.............................................500 Failure code [CA322] Inj #1 Open/Short Error.........................................502 Failure code [CA323] Inj #5 Open/Short Error.........................................504 Failure code [CA324] Inj #3 Open/Short Error.........................................506 Failure code [CA325] Inj #6 Open/Short Error.........................................508 Failure code [CA331] Inj #2 Open/Short Error.........................................510 Failure code [CA332] Inj #4 Open/Short Error.........................................512 40 Troubleshooting...............................................................................515 Troubleshooting by failure code (Display of code), Part 2....................................515 Troubleshooting by failure code (Display of code), Part 2................................517 Failure code [CA342] Calibration Code Incompatibility................................517 Failure code [CA351] Injectors Drive Circuit Error...................................518 Failure code [CA352] Sens Supply 1 Volt Low Error....................................520 Failure code [CA386] Sens Supply 1 Volt High Error...................................522 Failure code [CA428] Water in Fuel Sensor High Error.................................524 Failure code [CA429] Water in Fuel Sensor Low Error..................................526 Failure code [CA441] Battery Voltage Low Error.......................................528 Failure code [CA442] Battery Voltage High Error......................................530 Failure code [CA449] Rail Press Very High Error......................................532 Failure code [CA451] Rail Press Sensor High Error....................................536 Failure code [CA452] Rail Press Sensor Low Error.....................................538 Failure code [CA553] Rail Press High Error...........................................540 Failure code [CA559] Rail Press Low Error............................................542 Failure code [CA689] Eng Ne Speed Sensor Error.......................................544 Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................546 Failure code [CA757] All Persistent Data Lost Error..................................548 Failure code [CA778] Eng Bkup Speed Sensor Error.....................................550 Failure code [CA1633] KOMNET Datalink Timeout Error..................................552 Failure code [CA2185] Throt Sens Sup Volt High Error.................................554 Failure code [CA2186] Throt Sens Sup Volt Low Error..................................555 Failure code [CA2249] Rail Press Very Low Error......................................556 Failure code [CA2265] Electric Lift Pump High Error..................................558 Failure code [CA2266] Electric Lift Pump Low Error...................................560 Failure code [CA2555] Grid Htr Relay Volt High Error.................................562 Failure code [CA2556] Grid Htr Relay Volt Low Error..................................564 Failure code [D110KB] Battery Relay Drive S/C........................................566 Failure code [D196KA] Service Return Relay Disc......................................568 Failure code [D196KB] Service Return Relay S/C.......................................570 Failure code [DA25KP] Press. Sensor Power Abnormality................................572 Failure code [DA2RMC] Pump Comm. Abnormality.........................................574 Failure code [DA2SKQ] Model Selection Abnormality....................................576 40 Troubleshooting...............................................................................579 Troubleshooting by failure code (Display of code), Part 3....................................579 Troubleshooting by failure code (Display of code), Part 3................................582 Failure code [DAFRMC] Monitor Comm. Abnormality......................................582 Failure code [DHPAMA] F Pump Press Sensor Abnormality................................584 Failure code [DHPBMA] R Pump Press Sensor Abnormality................................586 Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality..................................588 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality.......................590 Failure code [DW43KA] Travel Speed Sol. Disc.........................................592 Failure code [DW43KB] Travel Speed Sol. S/C..........................................594 Failure code [DW45KA] Swing Brake Sol. Disc..........................................597 Failure code [DW45KB] Swing Brake Sol. S/C...........................................600 Failure code [DW91KA] Travel Junction Sol. Disc......................................602 Failure code [DW91KB] Travel Junction Sol. S/C.......................................604 Failure code [DWJ0KA] Merge-divider Sol. Disc........................................606 Failure code [DWJ0KB] Merge-divider Sol. S/C.........................................608 Failure code [DWK0KA] 2-stage Relief Sol. Disc.......................................610 Failure code [DWK0KB] 2-stage Relief Sol. S/C........................................612 Failure code [DXA0KA] PC-EPC Sol. Disc...............................................614 Failure code [DXA0KB] PC-EPC Sol. S/C................................................616 Failure code [DXE0KA] LS-EPC Sol. Disc...............................................618 Failure code [DXE0KB] LS-EPC Sol. S/C................................................620 Failure code [DXE4KA] Service Current EPC Disc.......................................622 Failure code [DXE4KB] Service Current EPC S/C........................................623 Failure code [DY20KA] Wiper Working Abnormality......................................624 Failure code [DY20MA] Wiper Parking Abnormality......................................626 Failure code [DY2CKB] Washer Drive S/C...............................................628 Failure code [DY2DKB] Wiper Drive (For) S/C..........................................630 Failure code [DY2EKB] Wiper Drive (Rev) S/C..........................................632 40 Troubleshooting...............................................................................635 Troubleshooting of electrical system (E-mode)................................................635 Troubleshooting of electrical system (E-mode)............................................638 Before carrying out troubleshooting of electrical system.............................638 Information contained in troubleshooting table.......................................640 E-1 Engine does not start............................................................641 E-2 Auto-decelerator does not operate................................................644 E-3 Automatic warming-up system does not operate.....................................646 E-4 Preheater does not operate.......................................................648 E-5 All work equipment, swing, and travel mechanism do not move......................650 E-6 Power maximizing function does not operate.......................................652 E-7 Machine monitor does not display at all..........................................653 E-8 Machine monitor does not display some items......................................654 E-9 Contents of display by machine monitor are different from applicable machine.....654 E-10 Fuel level monitor was lighted in red while engine running......................655 E-11 Engine coolant temperature gauge does not indicate normally.....................656 E-12 Hydraulic oil temperature gauge does not indicate normally......................658 E-13 Fuel level gauge does not indicate normally.....................................659 E-14 Swing lock monitor does not indicate normally...................................660 E-15 When monitor switch is operated, monitor displays nothing.......................662 E-16 Windshield wiper and window washer do not operate...............................664 E-17 Machine push-up function does not operate normally..............................668 E-18 Monitoring function fails to display “boom raise” normally......................670 E-19 Monitoring function fails to display “boom lower” normally......................671 E-20 Monitoring function fails to display “arm IN” normally..........................672 E-21 Monitoring function fails to display “arm OUT” normally.........................673 E-22 Monitoring function fails to display “bucket CURL” normally.....................674 E-23 Monitoring function fails to display “bucket DUMP” normally.....................675 E-24 Monitoring function fails to display “swing” normally...........................676 E-25 Monitoring function fails to display “travel” normally..........................678 E-26 Monitoring function fails to display “travel differential pressure” normally....680 E-27 Monitoring function fails to display “service” normally.........................682 E-28 KOMTRAX system does not operate normally........................................684 E-29 Air conditioner does not operate................................................686 E-30 Travel alarm does not sound or does not stop sounding...........................688 E-31 Horn does not sound.............................................................690 40 Troubleshooting...............................................................................693 Troubleshooting of hydraulic and mechanical system (H-mode)..................................693 Troubleshooting of hydraulic and mechanical system (H- mode).............................696 System chart for hydraulic and mechanical system.....................................696 Information contained in troubleshooting table.......................................698 H-1 All work equipment lack power, or travel and swing speeds are slow...............700 H-2 Engine speed sharply drops or engine stalls......................................702 H-3 No work equipment, swing or travel move..........................................703 H-4 Abnormal noise is heard from around hydraulic pump...............................703 H-5 Auto-decelerator does not work...................................................704 H-6 Fine control mode does not function or responds slow.............................704 H-7 Boom moves slowly or lacks power.................................................705 H-8 Arm moves slowly or lacks power..................................................706 H-9 Bucket moves slowly or lacks power...............................................707 H-10 Work equipment does not move in its single operation............................707 H-11 Work equipment has a bit too fast hydraulic drift...............................708 H-12 Work equipment has big time lag.................................................710 H-13 Other work equipment moves when relieving single circuit........................710 H-14 Power max. switch does not operate..............................................711 H-15 In compound operation, work equipment with larger load moves slowly.............711 H-16 In swing + boom RAISE operation, boom moves slowly..............................712 H-17 In swing + travel operation, travel speed drops sharply.........................712 H-18 Machine swerves in travel.......................................................713 H-19 Machine travels slowly..........................................................714 H-20 Machine cannot be easily steered or lacks power.................................715 H-21 Travel speed does not shift, or it is too slow or fast..........................716 H-22 Track shoe does not turn (on one side only).....................................717 H-23 Machine does not swing..........................................................718 H-24 Swing acceleration is poor, or swing speed is slow..............................720 H-25 Excessive overrun when stopping swing...........................................722 H-26 There is big shock when stopping swing..........................................723 H-27 Large sound is made when upper structure stops swinging.........................723 H-28 Swing hydraulic drift is too big................................................724 40 Troubleshooting...............................................................................727 Troubleshooting of engine (S-mode)...........................................................727 Troubleshooting of engine (S-mode).......................................................729 Method of using troubleshooting chart................................................729 S-1 Starting performance is poor.....................................................732 S-2 Engine does not start............................................................733 S-3 Engine does not pick up smoothly.................................................736 S-4 Engine stops during operations...................................................737 S-5 Engine does not rotate smoothly..................................................738 S-6 Engine lacks output (or lacks power).............................................739 S-7 Exhaust smoke is black (incomplete combustion)...................................740 S-8 Oil consumption is excessive (or exhaust smoke is blue)..........................741 S-9 Oil becomes contaminated quickly.................................................742 S-10 Fuel consumption is excessive...................................................743 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...........744 S-12 Oil pressure drops..............................................................745 S-13 Oil level rises (Entry of coolant or fuel)......................................746 S-14 Coolant temperature becomes too high (overheating)..............................747 S-15 Abnormal noise is made..........................................................748 S-16 Vibration is excessive..........................................................749 50 Disassembly and assembly......................................................................751 General information on disassembly and assembly..............................................751 General information on disassembly and assembly..........................................752 How to read this manual..............................................................752 Coating materials list...............................................................754 Special tools list...................................................................757 Sketches of special tools............................................................761 50 Disassembly and assembly......................................................................765 Engine and cooling system....................................................................765 Engine and cooling system................................................................766 Removal and installation of fuel supply pump assembly................................766 Removal and installation of engine front seal........................................769 Removal and installation of engine rear seal.........................................771 Removal and installation of cylinder head assembly...................................776 Removal and installation of radiator assembly........................................786 Removal and installation of hydraulic oil cooler assembly............................788 Removal and installation of aftercooler assembly.....................................790 Removal and installation of engine and hydraulic pump assembly.......................791 50 Disassembly and assembly......................................................................797 Power train..................................................................................797 Power train..............................................................................798 Removal and installation of final drive assembly.....................................798 Disassembly and assembly of final drive assembly.....................................799 Removal and installation of swing motor and swing machinery assembly.................807 Disassembly and assembly of swing motor and swing machinery assembly.................808 Removal and installation of swing circle assembly....................................815 50 Disassembly and assembly......................................................................817 Undercarriage and frame......................................................................817 Undercarriage and frame..................................................................818 Disassembly and assembly of carrier roller...........................................818 Disassembly and assembly of track roller assembly....................................819 Disassembly and assembly of idler assembly...........................................820 Disassembly and assembly of recoil spring............................................823 Removal and installation of sprocket.................................................825 Expansion and installation of track shoe assembly....................................826 Removal and installation of revolving frame assembly.................................827 Removal and installation of counterweight assembly...................................829 50 Disassembly and assembly......................................................................831 Hydraulic system.............................................................................831 Hydraulic system.........................................................................832 Removal and installation of center swivel joint assembly.............................832 Disassembly and assembly of center swivel joint assembly.............................834 Removal and installation of hydraulic tank assembly..................................835 Removal and installation of control valve assembly...................................837 Disassembly and assembly of control valve assembly...................................840 Removal and installation of hydraulic pump assembly..................................842 Removal and installation of oil seal in hydraulic pump input shaft...................845 Disassembly and assembly of work equipment PPC valve assembly........................846 Disassembly and assembly of travel PPC valve assembly................................847 Disassembly and assembly of hydraulic cylinder assembly..............................848 50 Disassembly and assembly......................................................................855 Work equipment...............................................................................855 Work equipment...........................................................................856 Removal and installation of work equipment assembly..................................856 50 Disassembly and assembly......................................................................861 Cab and its attachments......................................................................861 Cab and its attachments..................................................................862 Removal and installation of operator's cab assembly..................................862 Removal and installation of operator’s cab glass (stuck glass).......................864 Removal and installation of front window assembly....................................873 50 Disassembly and assembly......................................................................881 Electrical system............................................................................881 Electrical system........................................................................882 Removal and installation of work equipment assembly..................................882 Removal and installation of machine monitor..........................................884 Removal and installation of pump controller..........................................884 Removal and installation of KOMTRAX terminal.........................................885 Removal and installation of engine controller........................................885 90 Diagrams and drawings.........................................................................887 Hydraulic diagrams and drawings..............................................................887 90 Diagrams and drawings.........................................................................895 Electrical diagrams and drawings.............................................................895
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