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Komatsu PC400-6, PC400LC-6, PC450-6, PC450LC-6 Excavator Shop Manual 32001, 12001 and up – PDF DOWNLOAD
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Komatsu PC400-6, PC400LC-6, PC450-6, PC450LC-6 Excavator Shop Manual
Book Code: SEBM014508
MACHINE MODEL SERIAL NUMBER
PC400-6 32001 and up
PC400LC-6 32001 and up
PC450-6 12001 and up
PC450LC-6 12001 and up
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Description
Komatsu PC400-6, PC400LC-6, PC450-6, PC450LC-6 Excavator Shop Manual
FILE DETAILS:
Komatsu PC400-6, PC400LC-6, PC450-6, PC450LC-6 Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC400-6, PC400LC-6, PC450-6, PC450LC-6
Serial Number: 32001 and up, 12001 and up
Book Code: SEBM014508
Language: English
Pages: 841
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC400-6, PC400LC-6, PC450-6, PC450LC-6 Excavator Shop Manual
FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu PC400-6, PC400LC-6, PC450-6, PC450LC-6 Excavator Shop Manual
COVER..................................................................................................................................................... 1 CONTENTS.................................................................................................................................................. 2 01 GENERAL................................................................................................................................................ 28 SPECIFICATION DRAWINGS................................................................................................................................ 29 SPECIFICATIONS........................................................................................................................................ 32 WEIGHT TABLE.......................................................................................................................................... 38 FUEL, COOLANT AND LUBRICANTS.......................................................................................................................... 44 10 STRUCTURE AND FUNCTION................................................................................................................................. 46 PARTS RELATED TO ENGINE............................................................................................................................... 47 RADIATOR, OIL COOLER.................................................................................................................................. 49 POWER TRAIN........................................................................................................................................... 50 FINAL DRIVE........................................................................................................................................... 51 SWING CIRCLE.......................................................................................................................................... 52 SWING MACHINERY....................................................................................................................................... 54 TRACK FRAME, RECOIL SPRING............................................................................................................................ 55 TRACK SHOE............................................................................................................................................ 56 HYDRAULIC PIPING DRAWING.............................................................................................................................. 57 HYDRAULIC TANK, HYDRAULIC FILTER...................................................................................................................... 61 HYDRAULIC PUMP........................................................................................................................................ 62 CONTROL VALVE......................................................................................................................................... 81 SELF-REDUCING PRESSURE VALVE.......................................................................................................................... 92 SUCTION SAFETY VALVE.................................................................................................................................. 97 CLSS.................................................................................................................................................. 98 SWING MOTOR...........................................................................................................................................154 CENTER SWIVEL JOINT...................................................................................................................................160 TRAVEL MOTOR..........................................................................................................................................162 VALVE CONTROL.........................................................................................................................................171 WORK EQUIPMENT・SWING PPC VALVE........................................................................................................................172 TRAVEL PPC VALVE......................................................................................................................................176 SERVICE PPC VALVE.....................................................................................................................................180 PPC SAFETY LOCK VALVE.................................................................................................................................183 PPC ACCUMULATOR.......................................................................................................................................183 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE..............................................................................................................184 LS-EPC VALVE..........................................................................................................................................191 SOLENOID VALVE........................................................................................................................................192 BOOM HOLDING VALVE....................................................................................................................................194 WORK EQUIPMENT........................................................................................................................................197 AIR CONDITIONER.......................................................................................................................................198 ACTUAL ELECTRIC WIRING DIAGRAM........................................................................................................................199 ENGINE CONTROL........................................................................................................................................203 ELECTRONIC CONTROL SYSTEM.............................................................................................................................209 MACHINE MONITOR SYSTEM................................................................................................................................234 FRONT WINDOW AUTO PULL-UP SYSTEM......................................................................................................................244 20 TESTING AND ADJUSTING..................................................................................................................................246 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.........................................................................................................247 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS........................................................................................................248 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.............................................................................................................264 TESTING AND ADJUSTING.................................................................................................................................272 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.................................................................................................273 MEASURING ENGINE SPEED............................................................................................................................274 MEASURING EXHAUST COLOR...........................................................................................................................275 ADJUSTING VALVE CLEARANCE.........................................................................................................................276 MEASURING COMPRESSION PRESSURE....................................................................................................................277 MEASURING BLOW-BY PRESSURE........................................................................................................................277 TESTING AND ADJUSTING FUEL INJECTION TIMING.......................................................................................................278 MEASURING ENGINE OIL PRESSURE.....................................................................................................................280 TESTING AND ADJUSTING FAN BELT TENSION............................................................................................................281 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.................................................................................281 ADJUSTING ENGINE SPEED SENSOR.....................................................................................................................282 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....................................................................................................283 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE.................................................................................................284 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT.................................................................285 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE).....................................................................289 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE.........................................292 TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED).................................................................297 TESTING SOLENOID VALVE OUTPUT PRESSURE............................................................................................................298 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE.................................................................................301 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.........................................................................................................303 TESTING TRAVEL DEVIATION..........................................................................................................................304 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.......................................................................................305 MEASURING OIL LEAKAGE.............................................................................................................................307 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.................................................................................................309 TESTING CLEARANCE OF SWING CIRCLE BEARING.........................................................................................................310 TESTING WEAR OF SPROCKET..........................................................................................................................311 TESTING AND ADJUSTING TRACK SHOE TENSION..........................................................................................................312 BLEEDING AIR......................................................................................................................................313 TROUBLESHOOTING.......................................................................................................................................315 POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................................................316 SEQUENCE OF EVENTS IN TROUBLESHOOTING.............................................................................................................317 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................................................................318 CHECKS BEFORE TROUBLESHOOTING.....................................................................................................................326 CONNECTOR TYPES AND MOUNTING LOCATIONS............................................................................................................327 CONNECTOR ARRANGEMENT DIAGRAM.....................................................................................................................329 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................................................332 EXPLANATION OF CONTROL MECHANISM OF ELECTRICAL SYSTEM.............................................................................................342 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.............................................................................................343 METHOD OF USING JUDGEMENT TABLE...................................................................................................................352 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................354 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE..........................................................................................356 SERVICE CODE TABLE................................................................................................................................361 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)......................................................................................362 N-1 [E218] COMMUNICATION ABNORMALITY..........................................................................................................363 TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)............................................................365 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER SYSTEM...............................................366 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................367 JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS.......................................371 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM..................................................................................................373 E-1 ABNORMALITY IN ENGINE THROTTLE, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)......................................................375 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED..........................................................................376 E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED.....................................................................377 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED.....................................................................378 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED..........................................................................379 E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED............................................................380 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED.......................................................................................381 E-8 ENGINE DOES NOT START.....................................................................................................................382 E-9 ENGINE SPEED IS IRREGULAR.................................................................................................................384 a) IDLING SPEED IS IRREGULAR..............................................................................................................384 b) THERE IS HUNTING.......................................................................................................................386 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW).....................................................................................388 E-11 ENGINE DOES NOT STOP.....................................................................................................................390 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP).......................................................................392 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).........................................................................................................394 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................395 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).................................................................................399 S-2 ENGINE DOES NOT START.....................................................................................................................400 (1) ENGINE DOES NOT TURN..................................................................................................................400 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)..............................................................401 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)............................................................402 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)......................................................................................403 S-4 ENGINE STOPS DURING OPERATIONS............................................................................................................404 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................................................405 S-6 ENGINE LACKS OUTPUT (NO POWER)............................................................................................................406 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................................................407 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...................................................................................408 S-9 OIL BECOMES CONTAMINATED QUICKLY..........................................................................................................409 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................410 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..................................................................411 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...............................................................................412 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL).....................................................................................................413 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).........................................................................................414 S-15 ABNORMAL NOISE IS MADE...................................................................................................................415 S-16 VIBRATION IS EXCESSIVE...................................................................................................................416 TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)................................................................417 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM................................................................................418 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................419 JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS........................................427 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE.........................................................................................................429 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF).....................................................................431 C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED.......................................................................432 C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED.......................................................................434 C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED........................................................................436 C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED........................................................................438 C-6 [E207] SHORT CIRCUIT IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED...................................................................440 C-7 [E208] DISCONNECTION IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED...................................................................441 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED..........................................................................442 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED..........................................................................444 C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED..................................................................446 C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED..................................................................447 C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED........................................................................448 C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED...............................................................449 C-14 [E231] SHORT CIRCUIT IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED.................................................................450 C-15 [E235] DISCONNECTION IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED.................................................................451 C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED..........................................................................................452 C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED..............................................................................454 C-18 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED..............................................................................455 C-19 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.....................................................................456 C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED......................................................................457 C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED..........................................................................458 C-22 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED............................................................................459 C-23 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)...............................................................460 TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)................................................................462 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE.........................................................................................................463 F-1 BIT PATTERN 20-(1) (SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP..........................................................................465 F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP.........................................................................466 F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP.....................................................................467 F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP.....................................................................468 F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP.........................................................................469 F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP........................................................................470 F-7 BIT PATTERN 21-(1) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP....................................................................471 F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP....................................................................472 F-9 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP..................................................................................473 F-10 BIT PATTERN 22-(5) (KEROSENE MODE CONNECTION) DOES NOT LIGHT UP..........................................................................474 F-11 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP..................................................................................475 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)..........................................................................................476 PUMP MERGE/DIVIDER LOGIC, SOLENOID ACTUATION TABLE............................................................................................478 TABLE OF FAILURE MODES AND CAUSES.............................................................................................................479 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER........................................................................483 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS.................................................................................485 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE.....................................................................................................486 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)....................................................................................................486 H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE).........................................................................487 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR..........................................................................................487 H-7 BOOM IS SLOW OR LACKS POWER...............................................................................................................488 H-8 ARM IS SLOW OR LACKS POWER................................................................................................................490 H-9 BUCKET IS SLOW OR LACKS POWER.............................................................................................................492 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET)DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)........................................................493 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)............................................................................................493 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)................................................................................................494 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED....................................................................................494 H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED...................................................................495 H-15 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION..........................................................................................495 H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW..........................................................................495 H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW................................................................................................496 H-18 IN SWING + ARM, ARM IS SLOW..............................................................................................................496 H-19 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY........................................................................................496 H-20 TRAVEL DEVIATION.........................................................................................................................497 a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL...............................................................................................497 b) EXCESSIVE TRAVEL DEVIATION WHEN STARTING...............................................................................................497 H-21 TRAVEL SPEED IS SLOW.....................................................................................................................498 H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER.............................................................................................500 H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED...........................................................................502 H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).....................................................................................................502 H-25 DOES NOT SWING...........................................................................................................................503 a) DOES NOT SWING TO EITHER LEFT OR RIGHT.................................................................................................503 b) DOES NOT SWING IN ONE DIRECTION........................................................................................................503 H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW........................................................................................504 a) SWING ACCELERATION IS POOR.............................................................................................................504 H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING....................................................................................................506 a) ONE DIRECTION ONLY.....................................................................................................................506 b) BOTH DIRECTIONS........................................................................................................................506 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY).................................................................................507 H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING.............................................................................................507 H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING.......................................................................................................508 a) WHEN SWING HOLDING BRAKE IS RELEASED...................................................................................................508 b) WHEN SWING HOLDING BRAKE IS APPLIED....................................................................................................508 H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED.........................................................................................509 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)................................................................................................510 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.................................................................512 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM..................................................................................................514 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED, E[102] ERROR IN CLOCK DATA IS DISPLAYED....................................................518 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED.............................519 M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED.........................................................................................520 M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED...............................................................................520 M-5 [E108] ENGINE WATER TEMPERATURE 105℃ DETECTED IS DISPLAYED................................................................................521 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS..................................................522 a) NONE OF LAMPS ON MONITOR PANEL LIGHT UP................................................................................................522 b) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP.........................................................................................522 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT..............................................524 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)............................524 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH...............................................................525 a) (COOLANT LEVEL) FLASHES................................................................................................................525 b) (ENGINE OIL LEVEL) FLASHES.............................................................................................................526 c) (HYDRAULIC OIL LEVEL) FLASHES..........................................................................................................527 M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP..........................................................................528 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH.........................................................529 a) ALTERNATOR SYSTEM......................................................................................................................529 b) ENGINE OIL PRESSURE SYSTEM.............................................................................................................530 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH.................................................531 a) ALTERNATOR SYSTEM......................................................................................................................531 b) ENGINE OIL PRESSURE SENSOR SYSTEM......................................................................................................532 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH............................................533 a) (ENGINE OIL PRESSURE) FLASHES..........................................................................................................533 b) (COOLANT LEVEL) FLASHES................................................................................................................533 c) (BATTERY CHARGE) FLASHES...............................................................................................................533 d) (COOLANT TEMPERATURE) FLASHES..........................................................................................................534 e) (FUEL LEVEL) FLASHES...................................................................................................................534 f) (AIR CLEANER CLOGGING) FLASHES ........................................................................................................535 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....536 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS.................................................................................536 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL).....................................................537 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE..................................................................................................538 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY......................................................................................538 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL....................................................................................................539 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY...................................................................................................539 M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP.........................................................540 M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH.......................................................540 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING...................................................................................541 M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED......................................541 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM.......................................................................................................542 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM..............................................................................................543 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM.................................................................................................544 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM....................................................................................................545 M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM..............................................................................................546 M-30 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113)..............................................547 a) WIPER DOES NOT WORK....................................................................................................................547 b) WIPER SWITCH IS NOT BEING OPERATED BUT WIPER IS ACTUATED...............................................................................552 M-31 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114)......................................553 a) WASHER MOTOR DOES NOT WORK.............................................................................................................553 b) SWITCH IS NOT BEING OPERATED BUT WASHER IS ACTUATED....................................................................................554 M-32 ELECTRIC GREASE GUN DOES NOT WORK........................................................................................................556 30 DISASSEMBLY AND ASSEMBLY...............................................................................................................................557 METHOD OF USING MANUAL................................................................................................................................559 PRECAUTIONS WHEN CARRYING OUT OPERATION...............................................................................................................561 SPECIAL TOOL LIST.....................................................................................................................................563 SKETCHES OF SPECIAL TOOLS.............................................................................................................................569 STARTING MOTOR ASSEMBLY...............................................................................................................................577 REMOVAL AND INSTALLATION..........................................................................................................................577 ALTERNATOR ASSEMBLY...................................................................................................................................578 REMOVAL AND INSTALLATION..........................................................................................................................578 ENGINE OIL COOLER ASSEMBLY............................................................................................................................579 REMOVAL AND INSTALLATION..........................................................................................................................579 FUEL INJECTION PUMP ASSEMBLY..........................................................................................................................580 REMOVAL...........................................................................................................................................580 INSTALLATION......................................................................................................................................582 WATER PUMP ASSEMBLY...................................................................................................................................583 REMOVAL AND INSTALLATION..........................................................................................................................583 NOZZLE HOLDER ASSEMBLY................................................................................................................................584 REMOVAL AND INSTALLATION..........................................................................................................................584 TURBOCHARGER ASSEMBLY.................................................................................................................................585 REMOVAL AND INSTALLATION..........................................................................................................................585 THERMOSTAT ASSEMBLY...................................................................................................................................586 REMOVAL AND INSTALLATION..........................................................................................................................586 ENGINE FRONT SEAL.....................................................................................................................................587 REMOVAL AND INSTALLATION..........................................................................................................................587 ENGINE REAR SEAL......................................................................................................................................588 REMOVAL...........................................................................................................................................588 INSTALLATION......................................................................................................................................589 CYLINDER HEAD ASSEMBLY................................................................................................................................592 REMOVAL...........................................................................................................................................592 INSTALLATION......................................................................................................................................596 GOVERNOR MOTOR ASSEMBLY...............................................................................................................................599 REMOVAL...........................................................................................................................................599 INSTALLATION......................................................................................................................................599 AFTERCOOLER CORE ASSEMBLY.............................................................................................................................600 REMOVAL AND INSTALLATION..........................................................................................................................600 HYDRAULIC COOLER ASSEMBLY.............................................................................................................................601 REMOVAL...........................................................................................................................................601 INSTALLATION......................................................................................................................................602 RADIATOR, HYDRAULIC COOLER ASSEMBLY...................................................................................................................603 REMOVAL...........................................................................................................................................603 INSTALLATION......................................................................................................................................605 ENGINE, MAIN PUMP ASSEMBLY............................................................................................................................606 REMOVAL...........................................................................................................................................606 INSTALLATION......................................................................................................................................609 DAMPER ASSEMBLY.......................................................................................................................................610 REMOVAL AND INSTALLATION..........................................................................................................................610 FUEL TANK ASSEMBLY....................................................................................................................................611 REMOVAL AND INSTALLATION..........................................................................................................................611 CENTER SWIVEL JOINT ASSEMBLY..........................................................................................................................612 REMOVAL AND INSTALLATION..........................................................................................................................612 DISASSEMBLY AND ASSEMBLY..........................................................................................................................614 FINAL DRIVE ASSEMBLY..................................................................................................................................616 REMOVAL AND INSTALLATION..........................................................................................................................616 DISASSEMBLY.......................................................................................................................................617 ASSEMBLY..........................................................................................................................................621 TRAVEL MOTOR ASSEMBLY.................................................................................................................................627 DISASSEMBLY.......................................................................................................................................627 ASSEMBLY..........................................................................................................................................632 SPROCKET..............................................................................................................................................643 REMOVAL AND INSTALLATION..........................................................................................................................643 SWING MOTOR ASSEMBLY..................................................................................................................................644 REMOVAL AND INSTALLATION..........................................................................................................................644 DISASSEMBLY.......................................................................................................................................645 ASSEMBLY..........................................................................................................................................648 SWING MACHINERY ASSEMBLY..............................................................................................................................655 REMOVAL AND INSTALLATION..........................................................................................................................655 DISASSEMBLY.......................................................................................................................................656 ASSEMBLY..........................................................................................................................................660 REVOLVING FRAME ASSEMBLY..............................................................................................................................665 REMOVAL...........................................................................................................................................665 INSTALLATION......................................................................................................................................666 SWING CIRCLE ASSEMBLY.................................................................................................................................667 REMOVAL AND INSTALLATION..........................................................................................................................667 IDLER, RECOIL SPRING ASSEMBLY.........................................................................................................................668 REMOVAL AND INSTALLATION..........................................................................................................................668 IDLER ASSEMBLY........................................................................................................................................669 DISASSEMBLY.......................................................................................................................................669 ASSEMBLY..........................................................................................................................................670 RECOIL SPRING ASSEMBLY................................................................................................................................672 DISASSEMBLY.......................................................................................................................................672 ASSEMBLY..........................................................................................................................................673 TRACK ROLLER ASSEMBLY.................................................................................................................................674 REMOVAL AND INSTALLATION..........................................................................................................................674 DISASSEMBLY.......................................................................................................................................675 ASSEMBLY..........................................................................................................................................676 CARRIER ROLLER ASSEMBLY...............................................................................................................................678 REMOVAL AND INSTALLATION..........................................................................................................................678 DISASSEMBLY.......................................................................................................................................679 ASSEMBLY..........................................................................................................................................681 TRACK SHOE ASSEMBLY...................................................................................................................................683 REMOVAL AND INSTALLATION..........................................................................................................................683 HYDRAULIC TANK ASSEMBLY...............................................................................................................................684 REMOVAL...........................................................................................................................................684 INSTALLATION......................................................................................................................................685 MAIN PUMP ASSEMBLY....................................................................................................................................686 REMOVAL...........................................................................................................................................686 INSTALLATION......................................................................................................................................687 DISASSEMBLY.......................................................................................................................................688 ASSEMBLY..........................................................................................................................................694 MAIN PUMP INPUT SHAFT OIL SEAL........................................................................................................................709 REMOVAL AND INSTALLATION..........................................................................................................................709 CONTROL VALVE ASSEMBLY................................................................................................................................710 REMOVAL...........................................................................................................................................710 INSTALLATION......................................................................................................................................712 DISASSEMBLY.......................................................................................................................................713 ASSEMBLY..........................................................................................................................................719 PUMP MERGE/DIVIDER VALVE ASSEMBLY.....................................................................................................................726 DISASSEMBLY AND ASSEMBLY..........................................................................................................................726 PRESSURE COMPENSATION VALVE ASSEMBLY..................................................................................................................727 DISASSEMBLY AND ASSEMBLY..........................................................................................................................727 SERVO VALVE ASSEMBLY FOR FRONT PUMP...................................................................................................................728 REMOVAL AND INSTALLATION..........................................................................................................................728 SERVO VALVE ASSEMBLY FOR REAR PUMP....................................................................................................................729 REMOVAL AND INSTALLATION..........................................................................................................................729 LS-EPC SOLENOID VALVE ASSEMBLY........................................................................................................................730 REMOVAL AND INSTALLATION..........................................................................................................................730 SOLENOID VALVE ASSEMBLY...............................................................................................................................731 REMOVAL AND INSTALLATION..........................................................................................................................731 WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................................................................732 REMOVAL AND INSTALLATION..........................................................................................................................732 DISASSEMBLY.......................................................................................................................................733 ASSEMBLY..........................................................................................................................................734 TRAVEL PPC VALVE ASSEMBLY.............................................................................................................................735 REMOVAL AND INSTALLATION..........................................................................................................................735 DISASSEMBLY.......................................................................................................................................736 ASSEMBLY..........................................................................................................................................737 PPC SHUTTLE VALVE ASSEMBLY............................................................................................................................738 REMOVAL...........................................................................................................................................738 INSTALLATION......................................................................................................................................739 DISASSEMBLY.......................................................................................................................................740 ASSEMBLY..........................................................................................................................................741 BOOM LOCK VALVE ASSEMBLY..............................................................................................................................742 REMOVAL AND INSTALLATION..........................................................................................................................742 DISASSEMBLY AND ASSEMBLY..........................................................................................................................743 BOOM CYLINDER ASSEMBLY................................................................................................................................744 REMOVAL...........................................................................................................................................744 INSTALLATION......................................................................................................................................745 ARM CYLINDER ASSEMBLY.................................................................................................................................746 REMOVAL...........................................................................................................................................746 INSTALLATION......................................................................................................................................747 BUCKET CYLINDER ASSEMBLY..............................................................................................................................748 REMOVAL...........................................................................................................................................748 INSTALLATION......................................................................................................................................749 HYDRAULIC CYLINDER ASSEMBLY...........................................................................................................................750 DISASSEMBLY.......................................................................................................................................750 ASSEMBLY..........................................................................................................................................753 WORK EQUIPMENT ASSEMBLY...............................................................................................................................757 REMOVAL...........................................................................................................................................757 INSTALLATION......................................................................................................................................758 BUCKET ASSEMBLY.......................................................................................................................................759 REMOVAL...........................................................................................................................................759 INSTALLATION......................................................................................................................................760 ARM ASSEMBLY..........................................................................................................................................761 REMOVAL...........................................................................................................................................761 INSTALLATION......................................................................................................................................762 BUCKET, ARM ASSEMBLY..................................................................................................................................763 REMOVAL...........................................................................................................................................763 INSTALLATION......................................................................................................................................764 BOOM ASSEMBLY.........................................................................................................................................765 REMOVAL...........................................................................................................................................765 INSTALLATION......................................................................................................................................766 OPERATOR'S CAB ASSEMBLY...............................................................................................................................767 REMOVAL...........................................................................................................................................767 INSTALLATION......................................................................................................................................768 COUNTERWEIGHT ASSEMBLY................................................................................................................................769 REMOVAL AND INSTALLATION..........................................................................................................................769 AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................................................................770 REMOVAL AND INSTALLATION..........................................................................................................................770 CONDENSER ASSEMBLY....................................................................................................................................771 REMOVAL AND INSTALLATION..........................................................................................................................771 RECEIVER TANK ASSEMBLY................................................................................................................................772 REMOVAL AND INSTALLATION..........................................................................................................................772 AIR CONDITIONER UNIT ASSEMBLY.........................................................................................................................773 REMOVAL...........................................................................................................................................773 INSTALLATION......................................................................................................................................774 GOVERNOR, PUMP CONTROLLER ASSEMBLY....................................................................................................................775 REMOVAL AND INSTALLATION..........................................................................................................................775 MONITOR PANEL ASSEMBLY................................................................................................................................776 REMOVAL AND INSTALLATION..........................................................................................................................776 CONTROL STAND CASE....................................................................................................................................777 REMOVAL...........................................................................................................................................777 INSTALLATION......................................................................................................................................778 40 MAINTENANCE STANDARD...................................................................................................................................779 ENGINE MOUNT..........................................................................................................................................780 SWING MACHINERY.......................................................................................................................................781 SWING CIRCLE..........................................................................................................................................783 FINAL DRIVE...........................................................................................................................................785 SPROCKET..............................................................................................................................................787 TRACK FRAME AND RECOIL SPRING.........................................................................................................................789 IDLER.................................................................................................................................................790 CARRIER ROLLER........................................................................................................................................792 TRACK ROLLER..........................................................................................................................................793 TRACK SHOE............................................................................................................................................794 HYDRAULIC PUMP........................................................................................................................................798 CONTROL VALVE.........................................................................................................................................799 SELF-REDUCING PRESSURE VALVE..........................................................................................................................806 SUCTION-SAFETY VALVE..................................................................................................................................807 SWING MOTOR...........................................................................................................................................808 TRAVEL MOTOR..........................................................................................................................................809 WORK EQUIPMENT・SWING PPC VALVE........................................................................................................................810 TRAVEL PPC VALVE .....................................................................................................................................811 SERVICE PPC VALVE.....................................................................................................................................812 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE..............................................................................................................813 LS-EPC VALVE..........................................................................................................................................814 SOLENOID VALVE........................................................................................................................................815 CENTER SWIVEL JOINT...................................................................................................................................816 BOOM HOLDING VALVE....................................................................................................................................818 HYDRAULIC CYLINDER....................................................................................................................................819 WORK EQUIPMENT........................................................................................................................................822 DIMENSIONS OF WORK EQUIPMENT..........................................................................................................................826 90 OTHERS.................................................................................................................................................830 HYDRAULIC CIRCUIT DIAGRAM ............................................................................................................................831 BACK HOE..........................................................................................................................................831 LOADING SHOVEL....................................................................................................................................832 ELECTRIC CIRCUIT DIAGRAM .............................................................................................................................833 BACK HOE..........................................................................................................................................833 ELECTRIC CIRCUIT DIAGRAM (1/3) WITH POWER WINDOW..............................................................................................833 ELECTRIC CIRCUIT DIAGRAM (2/3) WITH POWER WINDOW..............................................................................................834 ELECTRIC CIRCUIT DIAGRAM (3/3) WITH POWER WINDOW..............................................................................................835 ELECTRIC CIRCUIT DIAGRAM (1/3) PC400-6 SERIAL NO.: 32250 AND UP PC450-6 SERIAL NO.: 12144 AND UP WITHOUT POWER WINDOW ........................836 ELECTRIC CIRCUIT DIAGRAM (2/3) PC400-6 SERIAL NO.: 32250 AND UP PC450-6 SERIAL NO.: 12144 AND UP WITHOUT POWER WINDOW.........................837 ELECTRIC CIRCUIT DIAGRAM (3/3) PC400-6 SERIAL NO.: 32250 AND UP PC450-6 SERIAL NO.: 12144 AND UP WITHOUT POWER WINDOW.........................838 LOADING SHOVEL....................................................................................................................................839 ELECTRIC CIRCUIT DIAGRAM (1/3)................................................................................................................839 ELECTRIC CIRCUIT DIAGRAM (2/3)................................................................................................................840 ELECTRIC CIRCUIT DIAGRAM (1/3)................................................................................................................841
KOMATSU PC400-6, PC400LC-6, PC450-6, PC450LC-6 EXCAVATOR SHOP MANUAL 32001, 12001 AND UP – PDF DOWNLOAD:
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