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Komatsu PC400-7, PC400LC-7 Hydraulic Excavator Shop Manual SEBM037602 – PDF DOWNLOAD
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Komatsu PC400-7, PC400LC-7 Hydraulic Excavator Shop Manual
MACHINE MODEL SERIAL NUMBER
PC400-7 50001 and up
PC400LC-7 50001 and up
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Description
Komatsu PC400-7, PC400LC-7 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC400-7, PC400LC-7 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC400-7, PC400LC-7
Serial Number: 50001 and up
Book Code: SEBM037602
Language: English
Pages: 761
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC400-7, PC400LC-7 Hydraulic 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 PC400-7, PC400LC-7 Hydraulic Excavator Shop Manual
COVER............................................................................................................................... 1 CONTENTS............................................................................................................................ 2 01 GENERAL.......................................................................................................................... 29 SPECIFICATION DRAWINGS.......................................................................................................... 30 SPECIFICATIONS.................................................................................................................. 32 WEIGHT TABLE.................................................................................................................... 34 FUEL, COOLANT AND LUBRICANTS.................................................................................................... 36 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD..................................................................................... 39 ENGINE RELATED PARTS............................................................................................................ 40 RADIATOR・OIL COOLER・AFTERCOOLER................................................................................................. 41 POWER TRAIN..................................................................................................................... 42 FINAL DRIVE..................................................................................................................... 43 SPROCKET........................................................................................................................ 45 SWING MACHINERY................................................................................................................. 47 SWING CIRCLE.................................................................................................................... 49 TRACK FRAME AND RECOIL SPRING................................................................................................... 50 IDLER........................................................................................................................... 52 CARRIER ROLLER.................................................................................................................. 54 TRACK ROLLER.................................................................................................................... 55 TRACK SHOE...................................................................................................................... 56 HYDRAULIC PIPING DRAWING........................................................................................................ 60 HYDRAULIC TANK.................................................................................................................. 62 HYDRAULIC PUMP.................................................................................................................. 63 LS(PC)-EPC VALVE................................................................................................................ 81 VARIABLE VOLUME VALVE........................................................................................................... 84 CONTROL VALVE................................................................................................................... 86 MAIN RELIEF VALVE............................................................................................................... 99 CLSS............................................................................................................................100 SELF PRESSURE REDUCING VALVE....................................................................................................103 SWING MOTOR.....................................................................................................................106 REVERSAL PREVENTION VALVE.......................................................................................................111 CENTER SWIVEL JOINT.............................................................................................................113 TRAVEL MOTOR....................................................................................................................114 TRAVEL JUNCTION VALVE...........................................................................................................125 VALVE CONTROL...................................................................................................................127 TRAVEL PPC SHUTTLE VALVE........................................................................................................128 WORK EQUIPMENT・SWING PPC VALVE..................................................................................................132 TRAVEL PPC VALVE................................................................................................................136 SERVICE PPC VALVE...............................................................................................................143 SOLENOID VALVE..................................................................................................................144 PPC ACCUMULATOR.................................................................................................................146 RETURN OIL FILTER...............................................................................................................147 BOOM HYDRAULIC DRIFT PREVENTION VALVE...........................................................................................148 ARM HYDRAULIC DRIFT PREVENTION VALVE............................................................................................153 QUICK RETURN VALVE..............................................................................................................157 LIFT CHECK VALVE................................................................................................................159 ATTACHMENT CIRCUIT SELECTOR VALVE...............................................................................................160 HOLDING VALVE...................................................................................................................162 HYDRAULIC CYLINDER..............................................................................................................167 WORK EQUIPMENT..................................................................................................................169 COMBUSTION HEATER AND PARTS RELATED TO HEATER...................................................................................175 ENGINE CONTROL..................................................................................................................177 ELECTRONIC CONTROL SYSTEM.......................................................................................................182 MONITOR SYSTEM (MULTI MONITOR SPECIFICATION)....................................................................................209 7-SEGMENT MONITOR SYSTEM........................................................................................................229 SENSOR..........................................................................................................................236 20 TESTING AND ADJUSTING............................................................................................................239 STANDARD VALUE TABLE FOR ENGINE.................................................................................................240 STANDARD VALUE TABLE FOR CHASSIS................................................................................................241 TESTING AND ADJUSTING...........................................................................................................250 TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE.........................................................................251 MEASURING ENGINE SPEED......................................................................................................253 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)..............................................................................254 MEASURING EXHAUST TEMPERATURE...............................................................................................255 MEASURING EXHAUST GAS COLOR.................................................................................................256 ADJUSTING VALVE CLEARANCE...................................................................................................257 MEASURING COMPRESSION PRESSURE..............................................................................................259 MEASURING BLOW-BY PRESSURE..................................................................................................261 MEASURING ENGINE OIL PRESSURE...............................................................................................262 HANDLING OF FUEL SYSTEM DEVICES.............................................................................................263 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM................................................................................263 MEASURING FUEL PRESSURE.....................................................................................................264 BLEEDING AIR FROM FUEL CIRCUIT..............................................................................................265 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE......................................................................................267 ADJUSTING ENGINE SPEED SENSOR...............................................................................................268 TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION..................................................................269 MEASURING CLEARANCE OF SWING CIRCLE BEARING.................................................................................270 TESTING AND ADJUSTING TRACK SHOE TENSION....................................................................................271 TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................272 MEASURING BASIC PRESSURE IN CONTROL CIRCUIT.................................................................................276 TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...............................................................277 TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT...............................................................280 MEASURING SOLENOID VALVE OUTPUT PRESSURE....................................................................................284 MEASURING PPC VALVE OUTPUT PRESSURE.........................................................................................287 ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES.......................................................................289 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT.................................................................290 RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT............................................................................291 MEASURING OIL LEAKAGE.......................................................................................................292 BLEEDING AIR FROM EACH PART.................................................................................................294 TESTING PROCEDURE OF DIODE..................................................................................................297 SPECIAL FUNCTIONS OF MONITOR PANEL (MULTI MONITOR SPECIFICATION)............................................................298 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER.......................................................................325 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM (STANDARD SPECIFICATION)...............................326 PM-CLINIC SERVICE...........................................................................................................328 TROUBLESHOOTING.................................................................................................................335 POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................................336 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................................337 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................................338 CHECKS BEFORE TROUBLESHOOTING...............................................................................................346 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING................................................................................347 CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM...................................................351 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................................368 T-BRANCH BOX AND T-BRANCH TABLE.............................................................................................390 TROUBLESHOOTING WHEN ERROR CODE“ELECTRICAL SYSTEM”AND FAILURE CODE“MECHANICAL SYSTEM”ARE DISPLAYED..........................393 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................................395 ERROR CODE IN ELECTRICAL SYSTEM [E112] (SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE).....397 ERROR CODE IN ELECTRICAL SYSTEM [E113] (SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)....399 ERROR CODE IN ELECTRICAL SYSTEM [E114] (SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM).................................401 ERROR CODE IN ELECTRICAL SYSTEM [E115] (ABNORMAL WINDSHIELD WIPER MOTION)...............................................403 ERROR CODE IN ELECTRICAL SYSTEM [E116] (ABNORMALITY IN RETRACTING WINDSHIELD WIPER).....................................405 ERROR CODE IN ELECTRICAL SYSTEM [E117] (ENG. CONTROLLER S-NET COMM. ERR.)...............................................407 ERROR CODE IN ELECTRICAL SYSTEM [E118] (PUMP CONTROLLER S-NET COMM. ERR.)...............................................409 ERROR CODE IN ELECTRICAL SYSTEM [E128] (MONITOR COMM. ABNORMALITY)......................................................411 ERROR CODE IN ELECTRICAL SYSTEM [E201] (SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)...............................413 ERROR CODE IN ELECTRICAL SYSTEM [E203] (SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)...............................414 ERROR CODE IN ELECTRICAL SYSTEM [E204] (SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)......................................416 ERROR CODE IN ELECTRICAL SYSTEM [E205] (SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)....................................417 ERROR CODE IN ELECTRICAL SYSTEM [E206] (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID).............................418 ERROR CODE IN ELECTRICAL SYSTEM [E211] (DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)..................................419 ERROR CODE IN ELECTRICAL SYSTEM [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)..................................420 ERROR CODE IN ELECTRICAL SYSTEM [E214] (DISCONNECTION IN MERGE/DIVIDE SOLENOID).........................................422 ERROR CODE IN ELECTRICAL SYSTEM [E215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID).......................................423 ERROR CODE IN ELECTRICAL SYSTEM [E216] (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)................................424 ERROR CODE IN ELECTRICAL SYSTEM [E217] (ABNORMAL INPUT MODEL CODE)......................................................425 ERROR CODE IN ELECTRICAL SYSTEM [E218] (S-NET COMM. DISC.)..............................................................427 ERROR CODE IN ELECTRICAL SYSTEM [E222] (SHORT-CIRCUITING IN LS-EPC SOLENOID)............................................429 ERROR CODE IN ELECTRICAL SYSTEM [E223] (DISCONNECTION IN LS-EPC SOLENOID SYSTEM)........................................430 ERROR CODE IN ELECTRICAL SYSTEM [E224] (F PUMP P. SENSOR ABNORMALITY)...................................................431 ERROR CODE IN ELECTRICAL SYSTEM [E225] (R PUMP P. SENSOR ABNORMALITY)...................................................433 ERROR CODE IN ELECTRICAL SYSTEM [E226] (PRESS. SENSOR POWER ABNORMALITY)................................................435 ERROR CODE IN ELECTRICAL SYSTEM [E227] (ABNORMALITY IN ENGINE ROTATION SENSOR)..........................................437 ERROR CODE IN ELECTRICAL SYSTEM [E228] (SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)..........................438 ERROR CODE IN ELECTRICAL SYSTEM [E232] (SHORT-CIRCUITING IN PC-EPC SOLENOID)............................................439 ERROR CODE IN ELECTRICAL SYSTEM [E233] (DISCONNECTION IN PC-EPC SOLENOID SYSTEM)........................................441 ERROR CODE IN ELECTRICAL SYSTEM [E238] (DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY).............................443 ERROR CODE IN ELECTRICAL SYSTEM [E245] (SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC).....................445 ERROR CODE IN ELECTRICAL SYSTEM [E246] (DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)........................446 ERROR CODE IN ELECTRICAL SYSTEM [E247] (ARM IN PPC PRESSURE SENSOR ABNORMALITY).........................................447 ERROR CODE IN ELECTRICAL SYSTEM [E248] (BUCKET CURL PPC PRESSURE SENSOR ABNORMALITY)....................................449 ERROR CODE IN ELECTRICAL SYSTEM [E257] (PUMP ABNORMALITY)...............................................................451 ERROR CODE IN ELECTRICAL SYSTEM [E315] (BATTERY RELAY DRIVE S/C)........................................................453 ERROR CODE IN ELECTRICAL SYSTEM [E91B] (ENGINE NE SENSOR PROBLEM).......................................................455 ERROR CODE IN ELECTRICAL SYSTEM [E91C] (ENGINE G SENSOR PROBLEM)........................................................456 ERROR CODE IN ELECTRICAL SYSTEM [E920] (ENGINE TYPE SELECTION ERROR)....................................................457 ERROR CODE IN ELECTRICAL SYSTEM [E921] (ENGINE TYPE MISMATCH)...........................................................459 ERROR CODE IN ELECTRICAL SYSTEM [E931] (FUEL DIAL SYS. ERROR)...........................................................460 ERROR CODE IN ELECTRICAL SYSTEM [E934] (ENGINE COOLANT SENSOR HI ERROR).................................................462 ERROR CODE IN ELECTRICAL SYSTEM [E936] (ENGINE OIL PRESS. SW. ERROR)....................................................464 ERROR CODE IN ELECTRICAL SYSTEM [E93C] (ENGINE BOOST SENSOR ERROR)......................................................466 ERROR CODE IN ELECTRICAL SYSTEM [E93D] (ENGINE FUEL TEMP. SENSOR ERROR).................................................468 ERROR CODE IN ELECTRICAL SYSTEM [E953] (ENGINE COMM. ABNORMALITY).......................................................470 ERROR CODE IN ELECTRICAL SYSTEM [E954] (SHORT ENGINE STARTER SW.).......................................................472 ERROR CODE IN ELECTRICAL SYSTEM [E955] (ENGINE S-NET ERROR).............................................................474 ERROR CODE IN ELECTRICAL SYSTEM [E956] (ENGINE POWER FAILURE (1)).......................................................476 ERROR CODE IN ELECTRICAL SYSTEM [E957] (ENGINE POWER FAILURE (2)).......................................................478 ERROR CODE IN ELECTRICAL SYSTEM [E95A] (ENGINE Q-ADJ. SW. SIGNAL ERROR).................................................480 ERROR CODE IN ELECTRICAL SYSTEM [E96A] (ENGINE COOLANT SENSOR LO ERROR).................................................481 ERROR CODE IN ELECTRICAL SYSTEM [E970] (PCV1 OVER CURRENT)..............................................................483 ERROR CODE IN ELECTRICAL SYSTEM [E971] (PCV2 OVER CURRENT)..............................................................484 ERROR CODE IN ELECTRICAL SYSTEM [E974] (PCV1 LINE CUT)..................................................................485 ERROR CODE IN ELECTRICAL SYSTEM [E975] (PCV2 LINE CUT)..................................................................486 ERROR CODE IN ELECTRICAL SYSTEM [E977] (RAIL PRESS. SENSOR ERROR).......................................................487 ERROR CODE IN ELECTRICAL SYSTEM [E979] (RAIL PRESS. HIGH)...............................................................489 ERROR CODE IN ELECTRICAL SYSTEM [E97A] (RAIL PRESS. ABNORMAL)...........................................................489 ERROR CODE IN ELECTRICAL SYSTEM [E97B] (RAIL PRESS. LOW)................................................................490 ERROR CODE IN ELECTRICAL SYSTEM [E97C] (RAIL PRESS. TOO LOW)............................................................492 ERROR CODE IN ELECTRICAL SYSTEM [E97D] (RAIL PRESS. OUT OF CONTROL).....................................................492 ERROR CODE IN ELECTRICAL SYSTEM [E980] (ENG. CONTROLLER ABNORMALITY)....................................................493 ERROR CODE IN ELECTRICAL SYSTEM [E981] (FUEL INJECTOR 1 DISC.)..........................................................495 ERROR CODE IN ELECTRICAL SYSTEM [E982] (FUEL INJECTOR 2 DISC.)..........................................................496 ERROR CODE IN ELECTRICAL SYSTEM [E983] (FUEL INJECTOR 3 DISC.)..........................................................497 ERROR CODE IN ELECTRICAL SYSTEM [E984] (FUEL INJECTOR 4 DISC.)..........................................................498 ERROR CODE IN ELECTRICAL SYSTEM [E985] (FUEL INJECTOR 5 DISC.)..........................................................499 ERROR CODE IN ELECTRICAL SYSTEM [E986] (FUEL INJECTOR 6 DISC.)..........................................................500 ERROR CODE IN ELECTRICAL SYSTEM [E98A] (FUEL INJECTOR 1-3 S/C)..........................................................501 ERROR CODE IN ELECTRICAL SYSTEM [E98B] (FUEL INJECTOR 4-6 S/C)..........................................................503 ERROR CODE IN MECHANICAL SYSTEM [A000N1] (ENGINE HIGH-IDLING SPEED OUT OF STANDARD).....................................505 ERROR CODE IN MECHANICAL SYSTEM [A000N2] (ENGINE LOW-IDLING SPEED OUT OF STANDARD)......................................505 FAILURE CODE IN MECHANICAL SYSTEM [AA10NX] (AIRCLEANER CLOGGING)........................................................506 FAILURE CODE IN MECHANICAL SYSTEM [AB00KE] (CHARGE VOLTAGE LOW).........................................................508 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG] (ENG. OIL PRESS. LOW)........................................................510 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK] (ENG. OIL LEVEL LOW).........................................................512 FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS] (ENG. WATER OVERHEAT)........................................................513 FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK] (ENG. WATER LVL LOW).........................................................514 FAILURE CODE IN MECHANICAL SYSTEM [B@HANS] (HYDR. OIL OVERHEAT).........................................................515 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...............................................................................516 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................................518 E-1 ENGINE DOES NOT START (THE ENGINE DOES NOT ROTATE)..................................................................519 E-2 PREHEATER DOES NOT OPERATE..........................................................................................522 E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK............................................................................524 E-4 AUTO-DECELERATOR DOES NOT OPERATE...................................................................................525 E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE....................................................................526 E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE......................................................................528 E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY..................................................................529 E-8 ATTACHMENT CIRCUIT DOES NOT CHANGE..................................................................................531 E-9 NO DISPLAY IN MONITOR PANEL AT ALL..................................................................................533 E-10 PART OF DISPLAY ON MONITOR PANEL IS MISSING........................................................................534 E-11 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL............................................................534 E-12 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING......................................................535 E-13 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY..........................................................536 E-14 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.........................................................538 E-15 FUEL GAUGE DOES NOT DISPLAY CORRECTLY..............................................................................539 E-16 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY......................................................................540 E-17 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED..............................................................542 E-18 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK.....................................................................544 E-19 ALARM BUZZER CANNOT BE CANCELLED...................................................................................548 E-20 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION........................................................549 E-21 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION........................................................550 E-22 "ARM IN" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION..........................................................551 E-23 "ARM DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION....................................................552 E-24 "BUCKET CURL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION.....................................................553 E-25 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION.................................................554 E-26 "SWING" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION...........................................................555 E-27 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION.........................................................557 E-28 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION...................................559 E-29 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION........................................................561 E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING..............................................................563 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).................................................................565 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM........................................................................566 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................................568 H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE LOW...................................................569 H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS.........................................................................570 H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE.............................................................................571 H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP..................................................................571 H-5 AUTO-DECELERATOR DOES NOT WORK......................................................................................572 H-6 FINE CONTROL MODE DOES NOT FUNCTION.................................................................................572 H-7 BOOM MOVES SLOWLY OR LACKS POWER....................................................................................573 H-8 ARM MOVES SLOWLY OR LACKS POWER.....................................................................................574 H-9 BUCKET MOVES SLOWLY OR LACKS POWER..................................................................................575 H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION...............................................................575 H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT..................................................................576 H-12 WORK EQUIPMENT HAS BIG TIME LAG....................................................................................577 H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT...........................................................577 H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK........................................................................577 H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK.............................................................................578 H-16 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY................................................579 H-17 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY.................................................................579 H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY......................................................................579 H-19 MACHINE SWERVES IN TRAVEL..........................................................................................580 H-20 MACHINE TRAVELS SLOWLY.............................................................................................581 H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER....................................................................582 H-22 TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED...........................................583 H-23 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)........................................................................584 H-24 MACHINE DOES NOT SWING.............................................................................................585 H-25 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW.................................................................586 H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING..............................................................................587 H-27 THERE IS BIG SHOCK WHEN STOPPING SWING.............................................................................588 H-28 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING.............................................................588 H-29 SWING NATURAL DRIFT IS TOO BIG.....................................................................................589 H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE.................................................................................590 H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED.................................................................590 TROUBLESHOOTING OF ENGINE (S MODE)..........................................................................................591 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................................592 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................593 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...........................................................596 S-2 ENGINE DOES NOT START...............................................................................................597 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................................................................600 S-4 ENGINE STOPS DURING OPERATIONS......................................................................................601 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...........................................................................602 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)................................................................................603 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)......................................................................604 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).............................................................605 S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................................606 S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................................607 S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)...........................................608 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).........................................................609 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...............................................................................610 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................611 S-15 ABNORMAL NOISE IS MADE.............................................................................................612 S-16 VIBRATION IS EXCESSIVE.............................................................................................613 30 DISASSEMBLY AND ASSEMBLY.........................................................................................................614 HOW TO READ THIS MANUAL.........................................................................................................615 PRECAUTIONS WHEN PERFORMING OPERATION...........................................................................................617 SPECIAL TOOL LIST...............................................................................................................619 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY..............................................................................626 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL....................................................................................633 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...................................................................................637 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY...........................................................................640 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY..............................................................................643 REMOVAL AND INSTALLATION OF NOZZLE TIP..........................................................................................646 REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY.............................................................................648 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...................................................................................649 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY.......................................................................651 REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY..................................................................653 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY...............................................................................658 REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................659 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................660 REMOVAL AND INSTALLATION OF SPROCKET............................................................................................667 REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...............................................................668 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY................................................................................669 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.............................................................................676 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...............................................................................678 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY......................................................................................679 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY..............................................................................682 EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY...............................................................................684 REMOVAL AND INSTALLATION OF OPERATOR’S CAB (STANDARD SPECIFICATION).............................................................686 REMOVAL AND INSTALLATION OF PUMP CONTROLLER (STANDARD SPECIFICATION)............................................................689 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY............................................................................690 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY..............................................................................693 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.............................................................................694 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY.............................................................................696 REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT..............................................................699 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY..............................................................................700 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY..............................................................................703 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY........................................................................707 DISASSEMBLY AND ASSEMBLY OF OF CENTER SWIVEL JOINT ASSEMBLY.....................................................................709 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VELVE ASSEMBLY...................................................................710 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...........................................................................711 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.........................................................................712 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY.............................................................................717 REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)..................................................................720 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY...............................................................................730 70 SUPPLEMENT FOR OFF-SET BOOM EXCAVATOR............................................................................................736 SPECIFICATION DRAWINGS..........................................................................................................737 SPECIFICATIONS..................................................................................................................738 WEIGHT TABLE....................................................................................................................739 TESTING AND ADJUSTING...........................................................................................................741 TROUBLESHOOTING.................................................................................................................742 MAINTENANCE STANDARD............................................................................................................744 90 OTHERS...........................................................................................................................754 HYDRAULIC CIRCUIT DIAGRAM (1/2).................................................................................................755 HYDRAULIC CIRCUIT DIAGRAM (2/2).................................................................................................756 ELECTRICAL CIRCUIT DIAGRAM (1/5) (EXTREME COLD SPEC.)...........................................................................757 ELECTRICAL CIRCUIT DIAGRAM (2/5) (EXTREME COLD SPEC.)...........................................................................758 ELECTRICAL CIRCUIT DIAGRAM (3/5) (EXTREME COLD SPEC.)...........................................................................759 ELECTRICAL CIRCUIT DIAGRAM (4/5) (EXTREME COLD SPEC.)...........................................................................760 ELECTRICAL CIRCUIT DIAGRAM (5/5) (EXTREME COLD SPEC.)...........................................................................761
KOMATSU PC400-7, PC400LC-7 HYDRAULIC EXCAVATOR SHOP MANUAL SEBM037602 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
