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Komatsu PC400-7, PC400LC-7, PC450-7, PC450LC-7Excavator Shop Manual SEBM033012 – PDF DOWNLOAD
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Description
Komatsu PC400-7, PC400LC-7, PC450-7, PC450LC-7 Excavator Shop Manual
FILE DETAILS:
Komatsu PC400-7, PC400LC-7, PC450-7, PC450LC-7Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC400-7, PC400LC-7, PC450-7, PC450LC-7
Serial Number: 50001 and up, 20001 and up
Book Code: SEBM033012
Language: English
Pages: 874
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC400-7, PC400LC-7, PC450-7, PC450LC-7Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC400-7, PC400LC-7, PC450-7, PC450LC-7Excavator Shop Manual
COVER.............................................................................................................................. 1 CONTENTS........................................................................................................................... 2 01 GENERAL......................................................................................................................... 36 SPECIFICATION DRAWINGS......................................................................................................... 37 SPECIFICATIONS................................................................................................................. 41 WEIGHT TABLE................................................................................................................... 47 FUEL, COOLANT AND LUBRICANTS................................................................................................... 51 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.................................................................................... 54 ENGINE RELATED PARTS........................................................................................................... 55 RADIATOR・OIL COOLER・AFTERCOOLER................................................................................................ 57 POWER TRAIN.................................................................................................................... 58 FINAL DRIVE.................................................................................................................... 59 SPROCKET....................................................................................................................... 61 SWING MACHINERY................................................................................................................ 63 SWING CIRCLE................................................................................................................... 65 TRACK FRAME AND RECOIL SPRING.................................................................................................. 66 IDLER.......................................................................................................................... 68 CARRIER ROLLER................................................................................................................. 70 TRACK ROLLER................................................................................................................... 71 TRACK SHOE..................................................................................................................... 72 HYDRAULIC PIPING DRAWING....................................................................................................... 76 HYDRAULIC TANK................................................................................................................. 78 HYDRAULIC PUMP................................................................................................................. 79 LS(PC)-EPC VALVE............................................................................................................... 98 VARIABLE VOLUME VALVE..........................................................................................................101 CONTROL VALVE..................................................................................................................103 CLSS...........................................................................................................................127 FUNCTIONS AND OPERATION BY VALVE...............................................................................................131 ATTACHMENT CIRCUIT SELECTOR VALVE..............................................................................................173 HOLDING VALVE..................................................................................................................175 SWING MOTOR....................................................................................................................181 REVERSAL PREVENTION VALVE......................................................................................................186 CENTER SWIVEL JOINT............................................................................................................188 TRAVEL MOTOR...................................................................................................................189 VALVE CONTROL..................................................................................................................200 TRAVEL PPC SHUTTLE VALVE.......................................................................................................201 WORK EQUIPMENT・SWING PPC VALVE.................................................................................................205 TRAVEL PPC VALVE...............................................................................................................209 SERVICE PPC VALVE..............................................................................................................216 SOLENOID VALVE.................................................................................................................217 PPC ACCUMULATOR................................................................................................................219 RETURN OIL FILTER..............................................................................................................220 HYDRAULIC CYLINDER.............................................................................................................221 WORK EQUIPMENT.................................................................................................................225 AIR CONDITIONER................................................................................................................233 ENGINE CONTROL.................................................................................................................234 ELECTRONIC CONTROL SYSTEM......................................................................................................239 MONITOR SYSTEM.................................................................................................................266 7-SEGMENT MONITOR SYSTEM.......................................................................................................287 SENSOR.........................................................................................................................294 20 TESTING AND ADJUSTING...........................................................................................................297 STANDARD VALUE TABLE FOR ENGINE................................................................................................298 STANDARD VALUE TABLE FOR CHASSIS (BACKHOE SPECIFICATION).......................................................................299 STANDARD VALUE TABLE FOR CHASSIS (LOADING SHOVEL SPECIFICATION)................................................................308 TESTING AND ADJUSTING..........................................................................................................317 TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE........................................................................318 MEASURING ENGINE SPEED.....................................................................................................320 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).............................................................................321 MEASURING EXHAUST TEMPERATURE..............................................................................................322 MEASURING EXHAUST GAS COLOR................................................................................................323 ADJUSTING VALVE CLEARANCE..................................................................................................324 MEASURING COMPRESSION PRESSURE.............................................................................................326 MEASURING BLOW-BY PRESSURE.................................................................................................328 MEASURING ENGINE OIL PRESSURE..............................................................................................329 HANDLING OF FUEL SYSTEM DEVICES............................................................................................330 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM...............................................................................330 MEASURING FUEL PRESSURE....................................................................................................331 BLEEDING AIR FROM FUEL CIRCUIT.............................................................................................332 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE.....................................................................................334 ADJUSTING ENGINE SPEED SENSOR..............................................................................................335 TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION.................................................................336 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION..............................................................337 MEASURING CLEARANCE OF SWING CIRCLE BEARING................................................................................338 TESTING AND ADJUSTING TRACK SHOE TENSION...................................................................................339 TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...........................................340 MEASURING BASIC PRESSURE IN CONTROL CIRCUIT................................................................................344 TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT..............................................................345 TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT..............................................................348 MEASURING SOLENOID VALVE OUTPUT PRESSURE...................................................................................353 MEASURING PPC VALVE OUTPUT PRESSURE........................................................................................356 ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES......................................................................358 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT................................................................359 RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT...........................................................................361 MEASURING OIL LEAKAGE......................................................................................................362 BLEEDING AIR FROM EACH PART................................................................................................365 TESTING PROCEDURE OF DIODE.................................................................................................368 SPECIAL FUNCTIONS OF MONITOR PANEL.........................................................................................369 SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL..............................................................................396 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER......................................................................415 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM.......................................................416 PM-CLINIC SERVICE..........................................................................................................418 TROUBLESHOOTING................................................................................................................425 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................426 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................................................427 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...........................................................................428 CHECKS BEFORE TROUBLESHOOTING..............................................................................................436 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...............................................................................437 CONNECTOR ARRANGEMENT DIAGRAM AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM..................................................441 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................................458 T- BRANCH BOX AND T- BRANCH ADAPTER TABLE..................................................................................494 CONNECTION TABLE OF FUSE BOX...............................................................................................497 TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED.....................498 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.........................................................................500 ERROR CODE IN ELECTRICAL SYSTEM [E112](SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE).....502 ERROR CODE IN ELECTRICAL SYSTEM [E113](SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)....504 ERROR CODE IN ELECTRICAL SYSTEM [E114](SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM).................................506 ERROR CODE IN ELECTRICAL SYSTEM [E115](ABNORMAL WINDSHIELD WIPER MOTION)...............................................508 ERROR CODE IN ELECTRICAL SYSTEM [E116](ABNORMALITY IN RETRACTING WINDSHIELD WIPER) ....................................510 ERROR CODE IN ELECTRICAL SYSTEM (E117](ENG. CONTROLLER S-NET COMM. ERR.)...............................................512 ERROR CODE IN ELECTRICAL SYSTEM (E118](PUMP CONTROLLER S-NET COMM. ERR.)...............................................514 ERROR CODE IN ELECTRICAL SYSTEM (E128](MONITOR COMM. ABNORMALITY)......................................................516 ERROR CODE IN ELECTRICAL SYSTEM (E201](SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)...............................518 ERROR CODE IN ELECTRICAL SYSTEM [E203](SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)...............................519 ERROR CODE IN ELECTRICAL SYSTEM [E204](SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)......................................521 ERROR CODE IN ELECTRICAL SYSTEM [E205](SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)....................................522 ERROR CODE IN ELECTRICAL SYSTEM [E206](SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID).............................523 ERROR CODE IN ELECTRICAL SYSTEM [E211](DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)..................................524 ERROR CODE IN ELECTRICAL SYSTEM [E213](DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)..................................525 ERROR CODE IN ELECTRICAL SYSTEM [E214](DISCONNECTION OF MERGE/DIVIDE SOLENOID).........................................527 ERROR CODE IN ELECTRICAL SYSTEM [E215](DISCONNECTION IN 2-STAGE RELIEF SOLENOID).......................................528 ERROR CODE IN ELECTRICAL SYSTEM [E216](DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)................................529 ERROR CODE IN ELECTRICAL SYSTEM [E217](ABNORMAL INPUT MODEL CODE)......................................................530 ERROR CODE IN ELECTRICAL SYSTEM [E218](S-NET COMM. DISC.)..............................................................532 ERROR CODE IN ELECTRICAL SYSTEM [E222](SHORT-CIRCUITING IN LS-EPC SOLENOID)............................................534 ERROR CODE IN ELECTRICAL SYSTEM [E223](DISCONNECTION IN LS-EPC SOLENOID SYSTEM)........................................535 ERROR CODE IN ELECTRICAL SYSTEM [E224](F PUMP P. SENSOR ABNORMALITY)...................................................536 ERROR CODE IN ELECTRICAL SYSTEM [E225](R PUMP P. SENSOR ABNORMALITY)...................................................538 ERROR CODE IN ELECTRICAL SYSTEM [E226](P. SENSOR POWER ABNORMALITY)....................................................540 ERROR CODE IN ELECTRICAL SYSTEM [E227](ABNORMALITY IN ENGINE ROTATION SENSOR) .........................................542 ERROR CODE IN ELECTRICAL SYSTEM [E228](SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)..........................543 ERROR CODE IN ELECTRICAL SYSTEM [E232](SHORT-CIRCUITING IN PC-EPC SOLENOID)............................................544 ERROR CODE IN ELECTRICAL SYSTEM [E233](DISCONNECTION IN PC-EPC SOLENOID SYSTEM)........................................546 ERROR CODE IN ELECTRICAL SYSTEM [E238](DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY).............................548 ERROR CODE IN ELECTRICAL SYSTEM [E245](SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC).....................550 ERROR CODE IN ELECTRICAL SYSTEM [E246](DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)........................551 ERROR CODE IN ELECTRICAL SYSTEM [E247](ARM IN PPC PRESSURE SENSOR ABNORMALITY).........................................552 ERROR CODE IN ELECTRICAL SYSTEM [E248](BUCKET CURL PPC PRESSURE SENSOR ABNORMALITY)....................................554 ERROR CODE IN ELECTRICAL SYSTEM [E257](PUMP ABNORMALITY)...............................................................556 ERROR CODE IN ELECTRICAL SYSTEM [E315](BATTERY RELAY DRIVE S/C)........................................................558 ERROR CODE IN ELECTRICAL SYSTEM [E91B](ENGINE NE SENSOR PROBLEM).......................................................560 ERROR CODE IN ELECTRICAL SYSTEM [E91C](ENGINE G SENSOR PROBLEM)........................................................561 ERROR CODE IN ELECTRICAL SYSTEM [E920](ENGINE TYPE SELECTION ERROR)....................................................562 ERROR CODE IN ELECTRICAL SYSTEM [E921](ENGINE TYPE MISMATCH)...........................................................564 ERROR CODE IN ELECTRICAL SYSTEM [E931](FUEL DIAL SYS. ERROR)...........................................................565 ERROR CODE IN ELECTRICAL SYSTEM [E934](ENGINE COOLANT SENSOR HI ERROR).................................................567 ERROR CODE IN ELECTRICAL SYSTEM [E936](ENGINE OIL PRESS. SW. ERROR)....................................................569 ERROR CODE IN ELECTRICAL SYSTEM [E93C](ENGINE BOOST SENSOR ERROR)......................................................571 ERROR CODE IN ELECTRICAL SYSTEM [E93D](ENGINE FUEL TEMP. SENSOR ERROR).................................................573 ERROR CODE IN ELECTRICAL SYSTEM [E953](ENGINE COMM. ABNORMALITY).......................................................575 ERROR CODE IN ELECTRICAL SYSTEM [E954](SHORT ENGINE STARTER SW.).......................................................577 ERROR CODE IN ELECTRICAL SYSTEM [E955](ENGINE S-NET ERROR).............................................................579 ERROR CODE IN ELECTRICAL SYSTEM [E956](ENGINE POWER FAILURE (1)).......................................................581 ERROR CODE IN ELECTRICAL SYSTEM [E957](ENGINE POWER FAILURE (2)).......................................................583 ERROR CODE IN ELECTRICAL SYSTEM [E95A](ENGINE Q-ADJ. SW. SIGNAL ERROR).................................................585 ERROR CODE IN ELECTRICAL SYSTEM [E96A](ENGINE COOLANT SENSOR LO ERROR).................................................586 ERROR CODE IN ELECTRICAL SYSTEM [E970](PCV1 OVER CURRENT)..............................................................588 ERROR CODE IN ELECTRICAL SYSTEM [E971](PCV2 OVER CURRENT)..............................................................589 ERROR CODE IN ELECTRICAL SYSTEM [E974](PCV1 LINE CUT)..................................................................590 ERROR CODE IN ELECTRICAL SYSTEM [E975](PCV2 LINE CUT)..................................................................591 ERROR CODE IN ELECTRICAL SYSTEM [E977](RAIL PRESS. SENSOR ERROR).......................................................592 ERROR CODE IN ELECTRICAL SYSTEM [E979](RAIL PRESS. HIGH)...............................................................594 ERROR CODE IN ELECTRICAL SYSTEM [E97A](RAIL PRESS. ABNORMAL)...........................................................594 ERROR CODE IN ELECTRICAL SYSTEM [E97B](RAIL PRESS. LOW)................................................................595 ERROR CODE IN ELECTRICAL SYSTEM [E97C](RAIL PRESS. TOO LOW)............................................................597 ERROR CODE IN ELECTRICAL SYSTEM [E97D](RAIL PRESS. CUT OF CONTROL).....................................................597 ERROR CODE IN ELECTRICAL SYSTEM [E980](ENG. CONTROLLER ABNORMALITY)....................................................598 ERROR CODE IN ELECTRICAL SYSTEM [E981](FUEL INJECTOR 1 DISC.)..........................................................600 ERROR CODE IN ELECTRICAL SYSTEM [E982](FUEL INJECTOR 2 DISC.)..........................................................601 ERROR CODE IN ELECTRICAL SYSTEM [E983](FUEL INJECTOR 3 DISC.)..........................................................602 ERROR CODE IN ELECTRICAL SYSTEM [E984](FUEL INJECTOR 4 DISC.)..........................................................603 ERROR CODE IN ELECTRICAL SYSTEM [E985](FUEL INJECTOR 5 DISC.)..........................................................604 ERROR CODE IN ELECTRICAL SYSTEM [E986](FUEL INJECTOR 6 DISC.)..........................................................605 ERROR CODE IN ELECTRICAL SYSTEM [E98A](FUEL INJECTOR 1-3 S/C)..........................................................606 ERROR CODE IN ELECTRICAL SYSTEM [E98B](FUEL INJECTOR 4-6 S/C)..........................................................608 ERROR CODE IN MECHANICAL SYSTEM [A000N1](ENGINE HIGH-IDLING SPEED OUT OF STANDARD).....................................610 ERROR CODE IN MECHANICAL SYSTEM [A000N2](ENGINE LOW-IDLING SPEED OUT OF STANDARD)......................................610 FAILURE CODE IN MECHANICAL SYSTEM [AA10NX](AIRCLEANER CLOGGING.........................................................611 FAILURE CODE IN MECHANICAL SYSTEM [AB00KE](CHARGE VOLTAGE LOW).........................................................613 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG](ENG. OIL PRESS. LOW)........................................................615 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK](ENG. OIL LEVEL LOW).........................................................617 FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS](ENG. WATER OVERHEAT)........................................................618 FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK](ENG. WATER LVL LOW).........................................................619 FAILURE CODE IN MECHANICAL SYSTEM [B@HANS](HYDR. OIL OVERHEAT).........................................................620 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..............................................................................621 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.........................................................................623 E-1 ENGINE DOES NOT START(THE ENGINE DOES NOT ROTATE)..................................................................624 E-2 PREHEATER DOES NOT OPERATE.........................................................................................627 E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK...........................................................................629 E-4 AUTO-DECELERATOR DOES NOT OPERATE..................................................................................630 E-5 ALL WORK EQUIPMENT,SWING AND TRAVEL DO NOT MOVE....................................................................631 E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE.....................................................................633 E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY.................................................................634 E-8 ATTACHMENT CIRCUIT DOES NOT CHANGE.................................................................................636 E-9 NO DISPLAY IN MONITOR PANEL AT ALL.................................................................................638 E-10 PART OF DISPLAY ON MONITOR PANEL IS MISSING.......................................................................639 E-11 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL...........................................................639 E-12 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING.....................................................640 E-13 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.........................................................641 E-14 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY........................................................643 E-15 FUEL GAUGE DOES NOT DISPLAY CORRECTLY.............................................................................644 E-16 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY.....................................................................645 E-17 WHEN MONITOR SWITCH IS OPERATED,NOTHING IS DISPLAYED..............................................................647 E-18 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK....................................................................649 E-19 ALARM BUZZER CANNOT BE CANCELLED..................................................................................653 E-20 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................654 E-21 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................655 E-22 "ARM IN" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION.........................................................656 E-23 "ARM DUMPING " IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....................................................657 E-24 "BUCKET CURL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION....................................................658 E-25 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...................................................659 E-26 "SWING" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION..........................................................660 E-27 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...........................................................662 E-28 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....................................664 E-29 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................................................666 E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING.............................................................668 E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM........................................................................670 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H MODE).................................................................681 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM.......................................................................682 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.........................................................................684 H-1 ALL WORK EQUIPMENT LACK POWER,OR TRAVEL AND SWING SPEEDS ARE SLOW..................................................685 H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS........................................................................686 H-3 NO WORK EQUIPMENT,TRAVEL OR SWING MOVE.............................................................................687 H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP.................................................................687 H-5 AUTO-DECELERATOR DOES NOT WORK.....................................................................................688 H-6 FINE CONTROL MODE DOES NOT FUNCTION................................................................................688 H-7 BOOM MOVES SLOWLY OR LACKS POWER...................................................................................689 H-8 ARM MOVES SLOWLY OR LACKS POWER....................................................................................690 H-9 BUCKET MOVES SLOWLY OR LACKS POWER.................................................................................691 H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION..............................................................691 H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT.................................................................692 H-12 WORK EQUIPMENT HAS BIG TIME LAG...................................................................................693 H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT..........................................................693 H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK.......................................................................693 H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK............................................................................694 H-16 IN COMPOUND OPERATION,WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY................................................695 H-17 IN SWING + BOOM RAISE OPERATION,BOOM MOVES SLOWLY.................................................................695 H-18 IN SWING + TRAVEL,TRAVEL SPEED DROPS SHARPLY......................................................................695 H-19 MACHINE SWERVES IN TRAVEL.........................................................................................696 H-20 MACHINE TRAVELS SLOWLY............................................................................................697 H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER...................................................................698 H-22 TRAVEL SPEED DOES NOT SHIFT,OR IT IS SLOWER OR FASTER THAN PRESET SPEED...........................................699 H-23 TRACK SHOE DOES NOT TURN(ON ONE SIDE ONLY)........................................................................700 H-24 MACHINE DOES NOT SWING............................................................................................701 H-25 SWING ACCELERATION IS POOR,OR SWING SPEED IS SLOW.................................................................702 H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING.............................................................................703 H-27 THERE IS BIG SHOCK WHEN STOPPING SWING............................................................................704 H-28 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING............................................................704 H-29 SWING NATURAL DRIFT IS TOO BIG....................................................................................705 H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE................................................................................706 H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED................................................................706 TROUBLESHOOTING OF ENGINE (S MODE).........................................................................................707 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................708 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................709 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..........................................................712 S-2 ENGINE DOES NOT START..............................................................................................713 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)................................................................716 S-4 ENGINE STOPS DURING OPERATIONS.....................................................................................717 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)...........................................................................718 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...............................................................................719 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)......................................................................720 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)............................................................721 S-9 OIL BECOMES CONTAMINATED QUICKLY...................................................................................722 S-10 FUEL CONSUMPTION IS EXCESSIVE.....................................................................................723 S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)..........................................724 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)........................................................725 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...............................................................................726 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)...................................................................727 S-15 ABNORMAL NOISE IS MADE............................................................................................728 S-16 VIBRATION IS EXCESSIVE............................................................................................729 30 DISASSEMBLY AND ASSEMBLY........................................................................................................730 HOW TO READ THIS MANUAL........................................................................................................731 COATING MATERIALS LIST.........................................................................................................733 SPECIAL TOOL LIST..............................................................................................................736 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.............................................................................746 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL...................................................................................753 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL..................................................................................757 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY..........................................................................760 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY.............................................................................763 REMOVAL AND INSTALLATION OF NOZZLE TIP.........................................................................................766 REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY............................................................................768 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY..................................................................................769 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY......................................................................771 REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY.................................................................773 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY..............................................................................778 REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...........................................................779 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...........................................................780 REMOVAL AND INSTALLATION OF SPROCKET...........................................................................................787 REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY..............................................................788 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY...............................................................................789 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY............................................................................796 DISASSEMBLY AND ASSEMBLY OF TRAVEL ROLLER ASSEMBLY.............................................................................798 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY.....................................................................................799 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY.............................................................................802 EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY..............................................................................804 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY......................................................................806 REMOVAL AND INSTALLATION OF OPERATOR'S CAB.....................................................................................808 REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY...................................................................................811 REMOVAL AND INSTALLATION OF PUMP CONTROLLER....................................................................................812 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER..................................................................................813 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY...........................................................................814 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY.............................................................................817 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY............................................................................818 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY............................................................................820 REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT.............................................................823 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY.............................................................................824 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY.............................................................................827 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY.......................................................................831 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY.......................................................................833 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................834 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY..........................................................................836 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY........................................................................838 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY............................................................................843 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS).................................................................846 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY..............................................................................856 90 OTHERS..........................................................................................................................862 HYDRAULIC CIRCUIT DIAGRAM (1/2)................................................................................................864 HYDRAULIC CIRCUIT DIAGRAM (2/2)................................................................................................865 ELECTRICAL CIRCUIT DIAGRAM (1/6)...............................................................................................866 ELECTRICAL CIRCUIT DIAGRAM (2/6)...............................................................................................867 ELECTRICAL CIRCUIT DIAGRAM (3/6)...............................................................................................868 ELECTRICAL CIRCUIT DIAGRAM (4/6)...............................................................................................869 ELECTRICAL CIRCUIT DIAGRAM (5/6)...............................................................................................870 ELECTRICAL CIRCUIT DIAGRAM (6/6)...............................................................................................871 AIR CONDITIONER ELECTRICAL CIRCUIT.............................................................................................872 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)...........................................................................................873 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE).............................................................................874
KOMATSU PC400-7, PC400LC-7, PC450-7, PC450LC-7EXCAVATOR SHOP MANUAL SEBM033012 – PDF DOWNLOAD:
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