HYDRAULIC EXCAVATOR PC340-6K PC340LC-6K PC340NLC-6K Shop Manual

SAFETY
SAFETY NOTICE
FOREWORD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
GENERAL
SPECIFICATION DRAWINGS
FUEL, COOLANT AND LUBRICANTS
STRUCTURE AND FUNCTION
PARTS RELATED TO ENGINE
RADIATOR, OIL COOLER
POWER TRAIN
FINAL DRIVE
SWING CIRCLE
SWING MACHINERY
TRACK FRAME, RECOIL SPRING
TRACK SHOE
HYDRAULIC PIPING DRAWING
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC PUMP
CONTROL VALVE
SELF- REDUCING PRESSURE VALVE SUCTION SAFETY VALVE
CLSS
SWING MOTOR
CENTER SWIVEL JOINT
TRAVEL MOTOR
VALVE CONTROL
WORK EQUIPMENT Ł SWING PPC VALVE
TRAVEL PPC VALVE SERVICE PPC VALVE
PPC SAFETY LOCK VALVE
PPC ACCUMULATOR
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
LS- EPC VALVE
SOLENOID VALVE
WORK EQUIPMENT
AIR CONDITIONER
ACTUAL ELECTRIC WIRING DIAGRAM
ELECTRIC CIRCUIT DIAGRAM
ENGINE CONTROL
ELECTRONIC CONTROL SYSTEM
MACHINE MONITOR SYSTEM
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW- BY PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING WATER PUMP BELT TENSION
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
ADJUSTING ENGINE SPEED SENSOR
MEASURING AIR SUPPLY PRESSURE ( BOOST PRESSURE)
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE ( SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE ( SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING CONTROL CIRCUIT OIL PRESSURE ( OIL PRESSURE WHEN SELF- PRESSURE IS REDUCED)
TESTING SOLENOID VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
TESTING TRAVEL DEVIATION
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
MEASURING OIL LEAKAGE
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING WEAR OF SPROCKET
TESTING AND ADJUSTING TRACK SHOE TENSION
BLEEDING AIR
POINTS TO REMEMBER WHEN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
SERVICE CODE TABLE
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER ( GOVERNOR CONTROL SYSTEM) ( E MODE)
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER ( GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER ( GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
E- 1 Abnormality in governor, pump controller power source ( controller LED is OFF)
E- 2 [ E308] Abnormality in fuel control dial input value is displayed
E- 3 [ E317] Abnormality ( disconnection) in motor drive system is displayed
E- 4 [ E318] Abnormality ( short circuit) in motor drive system is displayed
E- 5 [ E306] Abnormality in feedback potentiometer system is displayed
E- 6 [ E315] Abnormality ( short circuit) in battery relay output system is displayed
E- 7 [ E316] Abnormality ( step- out) in motor is displayed
E- 8 Engine does not start
E- 9 Engine speed is irregular
E- 10 Lack of output ( engine high idling speed is too low)
E- 11 Engine does not stop
E- 12 Defective operation of battery relay system ( engine does not stop)
TROUBLESHOOTING OF ENGINE SYSTEM ( S MODE)
S- 1 Starting performance is poor ( starting always takes time)
S- 2 Engine does not start
S- 3 Engine does not pick up smoothly ( follow- up is poor)
S- 4 Engine stops during operations
S- 5 Engine does not rotate smoothly ( hunting)
S- 6 Engine lacks output ( no power)
S- 7 Exhaust smoke is black ( incomplete combustion)
S- 8 Oil consumption is excessive ( or exhaust smoke is blue)
S- 9 Oil becomes contaminated quickly
S- 10 Fuel consumption is excessive
S- 11 Oil is in cooling water, or water spurts back, or water level goes down
S- 12 Oil pressure caution lamp lights up ( drop in oil pressure)
S- 13 Oil level rises ( water, fuel in oil)
S- 14 Water temperature becomes too high ( overheating)
S- 15 Abnormal noise is made
S- 16 Vibration is excessive
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER ( PUMP CONTROL SYSTEM) ( C MODE)
C- 1 Abnormality in controller power source system ( controller LED is OFF)
C- 2 [ E232] Short circuit in front pump TVC solenoid system is displayed
C- 3 [ E233] Disconnection in front pump TVC solenoid system is displayed
C- 4 [ E236] Short circuit in rear pump TVC solenoid system is displayed
C- 5 [ E237] Disconnection in rear pump TVC solenoid system is displayed
C- 6 [ E207] Short circuit in active mode ( boom) solenoid system is displayed
C- 7 [ E208] Disconnection in active mode ( boom) solenoid system is displayed
C- 8 [ E203] Short circuit in swing brake solenoid system is displayed
C- 9 [ E213] Disconnection in swing brake solenoid system is displayed
C- 10 [ E204] Short circuit in pump merge/ divider solenoid system is displayed
C- 11 [ E214] Disconnection in pump merge/ divider solenoid system is displayed
C- 12 [ E206] Short circuit in travel speed solenoid system is displayed
C- 13 [ E216] Disconnection in travel speed selector solenoid system is displayed
C- 14 [ E231] Short circuit in active mode ( swing) solenoid system is displayed
C- 15 [ E235] Disconnection in active mode ( swing) solenoid system is displayed
C- 16 [ E217] Model selection input error is displayed
C- 17 [ E222] Short circuit in LS- EPC solenoid system is displayed
C- 18 [ E223] Disconnection in LS- EPC solenoid system is displayed
C- 19 [ E224] Abnormality in front pump pressure sensor system is displayed
C- 20 [ E225] Abnormality in rear pump pressure sensor system is displayed
C- 21 [ E226] Abnormality in pressure sensor power source system is displayed
C- 22 [ E227] Abnormality in engine speed sensor system is displayed
C- 23 Abnormality in machine push- up solenoid system ( no service code displayed)
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER ( INPUT SIGNAL SYSTEM) ( F MODE)
F- 1 Bit pattern 20-( 1) Swing oil pressure switch does not light up
F- 2 Bit pattern 20-( 2) Travel oil pressure switch does not light up
F- 3 Bit pattern 20-( 3) Boom LOWER oil pressure switch does not light up
F- 4 Bit pattern 20-( 4) Boom RAISE oil pressure switch does not light up
F- 5 Bit pattern 20-( 5) Arm IN oil pressure switch does not light up
F- 6 Bit pattern 20-( 6) Arm OUT oil pressure switch does not light up
F- 7 Bit pattern 21-( 1) Bucket CURL oil pressure switch does not light up
F- 8 Bit pattern 21-( 2) Bucket DUMP oil pressure switch does not light up
F- 9 Bit pattern 21-( 3) Swing lock switch does not light up
F- 10 Bit pattern 22-( 5) Kerosene mode connection does not light up
F- 11 Bit pattern 22-( 6) L. H. knob switch does not light up
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM ( H MODE)
H- 1 Speeds of all work equipment, swing, travel are slow or lack power
H- 2 There is excessive drop in engine speed, or engine stalls
H- 3 No work equipment, travel, swing move H- 4 Abnormal noise generated ( around pump) H- 5 Auto- deceleration does not work ( when PPC shuttle valve is cause)
H- 6 Fine control ability is poor or response is poor H- 7 Boom is slow or lacks power
H- 8 Arm is slow or lacks power
H- 9 Bucket is slow or lacks power
H- 10 Work equipment ( boom, arm, bucket) does not move ( but travel and swing are normal)
H- 11 Excessive hydraulic drift ( boom, arm, bucket)
H- 12 Excessive time lag ( engine at low idling)
H- 13 Other equipment moves when single circuit is relieved H- 14 In L/ O, F/ O modes, work equipment speed is faster than specified speed
H- 15 Defective actuation of machine push- up function
H- 16 In compound operations, work equipment with larger load is slow
H- 17 In swing + boom RAISE, boom RAISE is slow
H- 18 In swing + arm, arm is slow
H- 19 In swing + travel, travel speed drops excessively
H- 20 Travel deviation
H- 21 Travel speed is slow
H- 22 Steering does not turn easily or lacks power
H- 23 Travel speed does not switch or is faster than specified speed
H- 24 Travel does not move ( one side only)
H- 25 Does not swing
H- 26 Swing acceleration is poor or swing speed is slow
H- 27 Excessive overrun when stopping swing
H- 28 Excessive shock when stopping swing ( one direction only) H- 29 Excessive abnormal noise when stopping swing
H- 30 Excessive hydraulic drift of swing
H- 31 Swing speed is faster than specified swing speed
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM ( M MODE)
M- 1 [ E101] Abnormality in error data is displayed [ E102] Error in clock data is displayed
M- 2 [ E103] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed
M- 3 [ E104] Air cleaner clogging detected is displayed
M- 4 [ E106] Drop in engine oil Hi pressure detected is displayed
M- 5 [ E108] Engine water temperature 105 ° C detected is displayed
M- 6 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds
M- 7 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out M- 8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine ( model)
M- 9 When starting switch is turned ON ( engine stopped), basic check items flash
M- 10 Preheating is not being used but ( preheating monitor) lights up
M- 11 When starting switch is turned ON and engine is started, basic check items flash
M- 12 When starting switch is turned ON ( engine stopped), caution items, emergency items flash ( battery, engine oil pressure lamps do not light up)
M- 13 When starting switch is turned ON and engine is started, caution items, emergency items flash ( when there is no abnormality in engine or items to check before troubleshooting)
M- 14 When starting switch is turned ON ( engine stopped), buzzer does not sound for 1 second Caution item flashes but buzzer does not sound
M- 15 No abnormality is displayed on monitor but buzzer sounds
M- 16 Night lighting on monitor panel does not light up ( liquid crystal display is normal)
M- 17 Coolant temperature gauge does not rise
M- 18 Coolant temperature gauge does not give any display ( none of gauge lamps light up during operation)
M- 19 Fuel level gauge always displays FULL
M- 20 Fuel level gauge does not give display
M- 21 Swing lock switch is turned ON ( LOCK) but ( swing lock monitor) does not light up
M- 22 Swing prolix switch is turned ON ( prolix), but ( swing lock monitor) does not flash
M- 23 Service meter does not advance while engine is running M- 24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed M- 25 Defective fuel level sensor system
M- 26 Defective coolant temperature sensor system
M- 27 Defective engine oil level sensor system
M- 28 Defective coolant level sensor system
M- 29 Defective hydraulic oil level sensor system
M- 30 Wiper does not work, or switch is not being used but wiper is actuated ( include E112, E113)
M- 31 Washer motor does not work, or switch is not being used but washer motor is actuated ( include E114)
30
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
REMOVAL OF STARTING MOTOR ASSEMBLY
INSTALLATION OF STARTING MOTOR ASSEMBLY
REMOVAL OF ALTERNATOR ASSEMBLY
INSTALLATION OF ALTERNATOR ASSEMBLY
REMOVAL OF ENGINE OIL COOLER ASSEMBLY
INSTALLATION OF ENGINE OIL COOLER ASSEMBLY
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
REMOVAL OF WATER PUMP ASSEMBLY
INSTALLATION OF WATER PUMP ASSEMBLY
REMOVAL OF NOZZLE HOLDER ASSEMBLY
INSTALLATION OF NOZZLE HOLDER ASSEMBLY
REMOVAL OF TURBOCHARGER ASSEMBLY
INSTALLATION OF TURBOCHARGER ASSEMBLY
REMOVAL OF THERMOSTAT ASSEMBLY
INSTALLATION OF THERMOSTAT ASSEMBLY
REMOVAL OF ENGINE FRONT SEAL
INSTALLATION OF ENGINE FRONT SEAL
REMOVAL OF ENGINE REAR SEAL
INSTALLATION OF ENGINE REAR SEAL
REMOVAL OF GOVERNOR MOTOR ASSEMBLY
INSTALLATION OF GOVERNOR MOTOR ASSEMBLY
REMOVAL OF CYLINDER HEAD ASSEMBLY
INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL OF AFTERCOOLER ASSEMBLY
INSTALLATION OF AFTERCOOLER ASSEMBLY
REMOVAL OF HYDRAULIC COOLER ASSEMBLY
INSTALLATION OF HYDRAULIC COOLER ASSEMBLY
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY
INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY
REMOVAL OF ENGINE, MAIN PUMP ASSEMBLY
INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY
REMOVAL OF DAMPER ASSEMBLY
INSTALLATION OF DAMPER ASSEMBLY
REMOVAL OF FUEL TANK ASSEMBLY
INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
REMOVAL OF FINAL DRIVE ASSEMBLY
INSTALLATION OF FINAL DRIVE ASSEMBLY
DISASSEMBLY OF FINAL DRIVE ASSEMBLY
ASSEMBLY OF FINAL DRIVE ASSEMBLY
DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY
ASSEMBLY OF TRAVEL MOTOR ASSEMBLY
DISASSEMBLY OF MAIN PUMP ASSEMBLY
ASSEMBLY OF MAIN PUMP ASSEMBLY
DISASSEMBLY OF PUMP MERGE/ DIVIDER VALVE ASSEMBLY
ASSEMBLY OF PUMP MERGE/ DIVIDER VALVE ASSEMBLY
DISASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY
ASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY
REMOVAL OF SERVO VALVE ASSEMBLY FOR FRONT PUMP
INSTALLATION OF SERVO VALVE ASSEMBLY FOR FRONT PUMP
REMOVAL OF SERVO VALVE ASSEMBLY FOR REAR PUMP
INSTALLATION OF SERVO VALVE ASSEMBLY FOR REAR PUMP
REMOVAL OF LS- EPC SOLENOID VALVE ASSEMBLY
INSTALLATION OF LS- EPC SOLENOID VALVE ASSEMBLY
REMOVAL OF SOLENOID VALVE ASSEMBLY
INSTALLATION OF SOLENOID VALVE ASSEMBLY
REMOVAL OF WORK EQUIPMENT PPC VALVE ASSEMBLY
INSTALLATION OF WORK EQUIPMENT, PPC VALVE ASSEMBLY
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
REMOVAL OF TRAVEL PPC VALVE ASSEMBLY
INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY
REMOVAL OF PPC SHUTTLE VALVE ASSEMBLY
INSTALLATION OF PPC SHUTTLE VALVE ASSEMBLY
DISASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY
ASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY
REMOVAL OF BOOM CYLINDER ASSEMBLY
INSTALLATION OF BOOM CYLINDER ASSEMBLY
REMOVAL OF ARM CYLINDER ASSEMBLY
INSTALLATION OF ARM CYLINDER ASSEMBLY
REMOVAL OF BUCKET CYLINDER ASSEMBLY
INSTALLATION OF BUCKET CYLINDER ASSEMBLY
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
REMOVAL OF WORK EQUIPMENT ASSEMBLY
INSTALLATION OF WORK EQUIPMENT ASSEMBLY
REMOVAL OF BUCKET ASSEMBLY
INSTALLATION OF BUCKET ASSEMBLY
REMOVAL OF ARM ASSEMBLY
INSTALLATION OF ARM ASSEMBLY
REMOVAL OF BUCKET, ARM ASSEMBLY
INSTALLATION OF BUCKET, ARM ASSEMBLY
REMOVAL OF BOOM ASSEMBLY
INSTALLATION OF BOOM ASSEMBLY
REMOVAL OF COUNTERWEIGHT ASSEMBLY
INSTALLATION OF COUNTERWEIGHT ASSEMBLY
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY
INSTALLATION OF CONDENSER ASSEMBLY
REMOVAL OF RECEIVER TANK ASSEMBLY
INSTALLATION OF RECEIVER TANK ASSEMBLY
REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY
INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
REMOVAL OF GOVERNOR, PUMP CONTROLLER ASSEMBLY
INSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY
REMOVAL OF MONITOR PANEL ASSEMBLY
INSTALLATION OF MONITOR PANEL ASSEMBLY
REMOVAL OF CONTROL STAND CASE
INSTALLATION OF CONTROL STAND CASE
MAINTENANCE STANDARD
ENGINE MOUNT
SWING MACHINERY SWING CIRCLE
FINAL DRIVE TRACK FRAME AND RECOIL SPRING
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
HYDRAULIC PUMP
CONTROL VALVE
SELF- REDUCING PRESSURE VALVE
SUCTION- SAFETY VALVE
SWING MOTOR
TRAVEL MOTOR
TRAVEL PPC VALVE
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
LS- EPC VALVE
SOLENOID VALVE HYDRAULIC CYLINDER
WORK EQUIPMENT