Komatsu PC400 -7E0,PC400LC-7E0,PC450 -7E0,PC450LC-7E0 Excavator Shop Manual PDF

Description

Komatsu PC400 -7E0,PC400LC-7E0,PC450 -7E0,PC450LC-7E0 Hydraulic Excavator Shop Manual SEN03578-05 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC400 -7E0,PC400LC-7E0,PC450 -7E0,PC450LC-7E0 Hydraulic Excavator Shop Manual SEN03578-05 – PDF DOWNLOAD

Language : English
Pages : 1029
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

• SERIAL NUMBERS
  PC400/400LC- 60001-60089
  PC400/400LC- 65001 and up
  PC450/450LC- 30001-30058
  PC450/450LC- 65001 and up

COVER . 1
00 Index and foreword . 0
Index . 3
Composition of shop manual 4
Table of contents . 6
Foreword and general information 15
Safety notice . 16
How to read the shop manual . 21
Explanation of terms for maintenance standard . 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines . 34
How to read electric wire code 37
Precautions when carrying out operation . 40
Method of disassembling and connecting push-pull type coupler . 43
Standard tightening torque table 46
Conversion table 50
01 Specification 0
Specification and technical data 57
Specification dimension drawings 58
Specifications 62
Weight table 68
Table of fuel, coolant and lubricants . 72
10 Structure, function and maintenance standard . 0
Engine and cooling system . 75
Engine related parts 76
Radiator, oil cooler and aftercooler 77
Power train . 79
Power train . 80
Final drive . 82
Sprocket 84
Swing machinery . 86
Swing circle 88
Undercarriage and frame . 91
Track frame and recoil spring . 92
Idler . 94
Carrier roller 96
Track roller 97
Track shoe 98
Hydraulic system, Part 1 103
Hydraulic equipment layout drawing 104
Hydraulic tank and filter . 106
Hydraulic pump 108
Hydraulic system, Part 2 133
Control valve . 134
CLSS 158
Functions and operation by valve 162
Merge-divider valve . 179
Attachment circuit selector valve . 204
Holding valve . 206
Hydraulic system, Part 3 213
Valve control . 214
PPC valve . 216
Solenoid valve 232
PPC accumulator . 234
Return oil filter . 235
Center swivel joint . 236
Travel motor 237
Swing motor . 249
Hydraulic cylinder 258
Work equipment 263
Work equipment 264
Dimensions of components 268
Cab and its attachments . 273
Air conditioner piping 274
Electrical system . 277
Engine control 278
Electronic control system . 287
Monitor system 312
Sensor 330
KOMTRAX system 333
20 Standard value table . 0
Standard service value table 337
Standard value table for engine related parts . 338
Standard value table for chassis related parts (Backhoe specification) 339
Standard value table for chassis related parts (Loading shovel specification) . 348
30 Testing and adjusting 0
Testing and adjusting, Part 1 . 359
Tools for testing, adjusting and troubleshooting 361
Measuring engine speed 365
Measuring air boost pressure 366
Measuring exhaust temperature . 367
Measuring exhaust gas color . 368
Adjusting valve clearance . 369
Measuring compression pressure 371
Measuring blow-by pressure 373
Measuring engine oil pressure . 374
Measuring EGR valve and bypass valve drive pressure . 375
Handling fuel system parts 376
Releasing residual pressure from fuel system 376
Measuring fuel pressure . 377
Handling during cylinder cut-out operation 378
Handling during no injection cranking operation . 378
Measuring fuel return rate and leakage 379
Bleeding air from fuel circuit 382
Checking fuel circuit for leakage . 384
Checking and adjusting fan belt and alternator belt tension . 385
Checking and adjusting air conditioner compressor belt tension 386
Measuring swing circle bearing clearance 387
Checking and adjusting track shoe tension . 388
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits 389
Measuring control circuit basic pressure 393
Checking and adjusting pump PC control circuit oil pressure . 394
Checking and adjusting pump LS control circuit oil pressure . 397
Measuring solenoid valve output pressure 402
Measuring PPC valve output pressure . 405
Adjusting play of work equipment and swing PPC valves . 406
Inspecting locations of hydraulic drift of work equipment . 407
Releasing residual pressure from hydraulic circuit 409
Measuring oil leakage amount 410
Bleeding air from various parts . 413
Testing and adjusting, Part 2 . 417
Special functions of machine monitor 418
Testing and adjusting, Part 3 . 447
Procedure for turning on KOMTRAX terminal . 448
Indication by KOMTRAX terminal lamps 451
Handling voltage circuit of engine controller . 454
Preparation work for troubleshooting of electrical system . 455
Procedure for testing diodes 460
Pm clinic service . 461
Undercarriage troubleshooting report 468
40 Troubleshooting 0
Failure code table and fuse locations . 471
Failure codes table . 472
Before carrying out troubleshooting when failure code is displayed 476
Information related to troubleshooting 481
Points to remember when troubleshooting . 482
Sequence of events in troubleshooting . 483
Checks before troubleshooting . 484
Classification and troubleshooting steps 485
Information in troubleshooting table 486
Connection table for connector pin numbers 491
T- branch box and T- branch adapter table . 527
Troubleshooting by failure code (Display of code), Part 1 . 531
Failure code [AA10NX] Aircleaner Clogging . 534
Failure code [AB00KE] Charge Voltage Low 536
Failure code [B@BAZG] Eng Oil Press. Low 538
Failure code [B@BAZK] Eng. Oil Level Low 540
Failure code [B@BCNS] Eng. Water Overheat . 542
Failure code [B@BCZK] Eng. Water Lvl Low 544
Failure code [B@HANS] Hydr. Oil Overheat 546
Failure code [CA111] ECM Critical Internal Failure 548
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 550
Failure code [CA122] Chg Air Press Sensor High Error 551
Failure code [CA123] Chg Air Press Sensor Low Error . 553
Failure code [CA131] Throttle Sensor High Error . 554
Failure code [CA132] Throttle Sensor Low Error 556
Failure code [CA135] Eng Oil Press Sensor High Error 557
Failure code [CA141] Eng Oil Press Sensor Low Error . 559
Failure code [CA144] Coolant Temp Sens High Error . 560
Failure code [CA145] Coolant Temp Sens Low Error 562
Failure code [CA153] Chg Air Temp Sensor High Error . 564
Failure code [CA154] Chg Air Temp Sensor Low Error 566
Failure code [CA187] Sens Supply 2 Volt Low Error . 568
Failure code [CA221] Ambient Press Sens High Error 570
Failure code [CA222] Ambient Press Sens Low Error . 572
Failure code [CA227] Sens Supply 2 Volt High Error 573
Failure code [CA234] Eng Overspeed 575
Failure code [CA238] Ne Speed Sens Supply Volt Error 576
Failure code [CA263] Fuel Temp Sensor High Error 578
Failure code [CA265] Fuel Temp Sensor Low Error . 580
Failure code [CA271] IMV/PCV1 Short Error . 581
Failure code [CA272] IMV/PCV1 Open Error 582
Failure code [CA273] PCV2 Short Error . 584
Failure code [CA274] PCV2 Open Error 585
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error 586
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error 588
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error 590
Failure code [CA325] Inj #6 (L/B#6) Open/Short Error 592
Failure code [CA331] Inj #2 (L/B#2) Open/Short Error 594
Failure code [CA332] Inj #4 (L/B#4) Open/Short Error 596
Troubleshooting by failure code (Display of code), Part 2 . 599
Failure code [CA342] Calibration Code Incompatibility . 601
Failure code [CA351] Injectors Drive Circuit Error 602
Failure code [CA352] Sens Supply 1 Volt Low Error . 604
Failure code [CA386] Sens Supply 1 Volt High Error 606
Failure code [CA441] Battery Voltage Low Error 608
Failure code [CA442] Battery Voltage High Error . 610
Failure code [CA449] Rail Press Very High Error . 612
Failure code [CA451] Rail Press Sensor High Error . 616
Failure code [CA452] Rail Press Sensor Low Error 618
Failure code [CA553] Rail Press High Error 620
Failure code [CA554] Rail Press Sensor In Range Error . 621
Failure code [CA559] Rail Press Low Error . 622
Failure code [CA689] Eng Ne Speed Sensor Error 626
Failure code [CA731] Eng Bkup Speed Sens Phase Error 628
Failure code [CA757] All Persistent Data Lost Error . 629
Failure code [CA778] Eng Bkup Speed Sensor Error 630
Failure code [CA1228] EGR Valve Servo Error 1 . 632
Failure code [CA1625] EGR Valve Servo Error 2 . 633
Failure code [CA1633] KOMNET Datalink Timeout Error . 634
Failure code [CA2185] Throt Sens Sup Volt High Error 636
Failure code [CA2186] Throt Sens Sup Volt Low Error . 638
Failure code [CA2249] Rail Press Very Low Error . 639
Failure code [CA2271] EGR Valve Lift Sens High Error 640
Failure code [CA2272] EGR Valve Lift Sens Low Error . 642
Failure code [CA2351] EGR Valve Sol Current High Error 644
Failure code [CA2352] EGR Valve Sol Current Low Error . 646
Failure code [CA2555] Grid Htr Relay Volt Low Error . 648
Failure code [CA2556] Grid Htr Relay Volt High Error 650
Failure code [D110KB] Battery Relay Drive Short Circuit . 652
Failure code [D196KA] Service Return Relay Open Circuit . 654
Failure code [D196KB] Service Return Relay Short Circuit 656
Failure code [DA25KP] 5V Sensor 1 Power Abnormality . 658
Failure code [DA80MA] Auto. Lub. Abnormal . 660
Troubleshooting by failure code (Display of code), Part 3 . 663
Failure code [DA2RMC] Pump Comm. Abnormality 666
Failure code [DA2SKQ] Model Selection Abnormality . 668
Failure code [DAFRMC] Monitor Comm. Abnormality . 670
Failure code [DGH2KB] Hydr Oil Sensor Short Circuit . 672
Failure code [DHPAMA] F Pump Press Sensor Abnormality . 674
Failure code [DHPBMA] R Pump Press Sensor Abnormality . 676
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality . 678
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 680
Failure code [DW43KA] Travel Speed Sol. Open Circuit 682
Failure code [DW43KB] Travel Speed Sol. Short Circuit . 684
Failure code [DW45KA] Swing Brake Sol. Open Circuit . 686
Failure code [DW45KB] Swing Brake Sol. Short Circuit 690
Failure code [DW91KA] Travel Junction Sol. Open Circuit . 692
Failure code [DW91KB] Travel Junction Sol. Short Circuit 694
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit . 696
Failure code [DWJ0KB] Merge-Divider Sol. Short Circuit 698
Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit 700
Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit . 702
Failure code [DXA0KA] PC-EPC Sol. Open Circuit 704
Failure code [DXA0KB] PC-EPC Sol. Short Circuit . 706
Failure code [DXE0KA] LS-EPC Sol. Open Circuit 708
Failure code [DXE0KB] LS-EPC Sol. Short Circuit . 710
Failure code [DXE4KA] Service Current EPC Open Circuit 712
Failure code [DXE4KB] Service Current EPC Short Circuit . 713
Failure code [DY20KA] Wiper Working Abnormality . 714
Failure code [DY20MA] Wiper Parking Abnormality . 716
Failure code [DY2CKB] Washer Drive Short Circuit 718
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit . 720
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit . 722
Troubleshooting of electrical system (E-mode) . 725
Before carrying out troubleshooting of electrical system 728
Information contained in troubleshooting table 730
E-1 Engine does not start . 731
E-2 Auto-decelerator does not operate . 734
E-3 Automatic warming-up does not operate . 736
E-4 Preheater does not operate 738
E-5 All work equipment, swing, and travel mechanism do not move . 740
E-6 Power maximizing function does not operate 742
E-7 Machine monitor does not display at all . 744
E-8 Machine monitor does not display some items . 746
E-9 Contents of display by machine monitor are different from applicable machine 746
E-10 Fuel level monitor was lighted in red while engine running . 747
E-11 Engine coolant temperature gauge does not indicate normally 748
E-12 Hydraulic oil temperature gauge does not indicate normally . 750
E-13 Fuel level gauge does not operate normally . 751
E-14 Swing lock monitor does not indicate normally 752
E-15 When monitor switch is operated, monitor displays nothing 754
E-16 Windshield wiper does not operate 756
E-17 Machine push-up function does not operate normally . 760
E-18 Monitoring function fails to display “boom RAISE” normally . 762
E-19 Monitoring function fails to display “boom LOWER” normally . 764
E-20 Monitoring function fails to display “arm IN” normally . 766
E-21 Monitoring function fails to display “arm OUT” normally 768
E-22 Monitoring function fails to display “bucket CURL” normally 770
E-23 Monitoring function fails to display “bucket DUMP” normally 772
E-24 Monitoring function fails to display “swing” normally 774
E-25 Monitoring function fails to display “travel” normally . 776
E-26 Monitoring function fails to display “travel differential pressure” normally . 778
E-27 Monitoring function fails to display “service” normally 780
E-28 The KOMTRAX system does not operate normally . 782
E-29 Air conditioner does not operate . 784
E-30 Travel alarm does not sound or does not stop sounding 786
E-31 Horn does not sound 788
Troubleshooting of hydraulic and mechanical system (H-mode) . 791
System chart for hydraulic and mechanical system 794
Information contained in troubleshooting table 796
H-1 All work equipment lack power, or travel and swing speeds are slow 798
H-2 Engine speed sharply drops or engine stalls . 800
H-3 No work equipment, swing or travel move . 801
H-4 Abnormal noise is heard from around hydraulic pump 801
H-5 Auto-decelerator does not work 802
H-6 Fine control mode does not function or responds slow 802
H-7 Boom moves slowly or lacks power 803
H-8 Arm moves slowly or lacks power . 804
H-9 Bucket moves slowly or lacks power 805
H-10 Work equipment does not move in its single operation . 805
H-11 Work equipment has a bit too fast hydraulic drift 806
H-12 Work equipment has big time lag 808
H-13 Other work equipment moves when relieving single circuit . 808
H-14 Power max. switch does not operate . 808
H-15 Machine push-up function does not operate 809
H-16 In compound operation of work equipment, speed of part loaded more is low 810
H-17 When machine swings and raises boom simultaneously, boom rising speed is low . 810
H-18 When machine swings and travels simultaneously, travel speed lowers largely 810
H-19 Machine deviates during travel . 811
H-20 Travel speed is low 812
H-21 Machine is not steered well or steering power is low . 813
H-22 Travel speed does not change or travel speed is low or high 814
H-23 Travel system does not move (only one side) 815
H-24 Upper structure does not swing . 816
H-25 Swing acceleration or swing speed is low . 818
H-26 Upper structure overruns remarkably when it stops swinging . 820
H-27 Large shock is made when upper structure stops swinging 821
H-28 Large sound is made when upper structure stops swinging 821
H-29 Hydraulic drift of swing is large 822
H-30 Attachment circuit is not changed 823
H-31 Oil flow in attachment circuit cannot be controlled 823
Troubleshooting of engine (S-mode) 825
Method of using troubleshooting chart . 828
S-1 Starting performance is poor 832
S-2 Engine does not start . 834
S-3 Engine does not pick up smoothly 838
S-4 Engine stops during operations 839
S-5 Engine does not rotate smoothly . 840
S-6 Engine lacks output (or lacks power) 841
S-7 Exhaust smoke is black (incomplete combustion) 842
S-8 Oil consumption is excessive (or exhaust smoke is blue) . 843
S-9 Oil becomes contaminated quickly 844
S-10 Fuel consumption is excessive 845
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 846
S-12 Oil pressure drops . 847
S-13 Oil level rises (Entry of coolant or fuel) . 848
S-14 Coolant temperature becomes too high (overheating) . 850
S-15 Abnormal noise is made . 851
S-16 Vibration is excessive . 852
50 Disassembly and assembly . 0
General information on disassembly and assembly . 855
How to read this manual . 856
Coating materials list 858
Special tools list 861
Sketches of special tools . 865
Engine and cooling system . 871
Removal and installation of fuel supply pump assembly . 872
Removal and installation of fuel injector assembly 876
Removal and installation of engine front seal . 882
Removal and installation of engine rear seal 885
Removal and installation of cylinder head assembly 890
Removal and installation of radiator assembly . 899
Removal and installation of hydraulic oil cooler assembly . 901
Removal and installation of aftercooler assembly 903
Removal and installation of engine and hydraulic oil pump assembly 904
Power train . 913
Removal and installation of travel motor and final drive assembly . 914
Disassembly and assembly of final drive assembly 915
Removal and installation of swing motor and swing machinery assembly 923
Disassembly and assembly of swing machinery assembly 924
Removal and installation of swing circle assembly . 931
Undercarriage and frame . 933
Disassembly and assembly of carrier roller assembly . 934
Disassembly and assembly of track roller assembly . 936
Removal and installation of idler, recoil spring assembly . 937
Disassembly and assembly of idler assembly 938
Disassembly and assembly of recoil spring assembly 941
Removal and installation of sprocket 943
Expansion and installation of track shoe assembly . 944
Removal and installation of revolving frame assembly 946
Removal and installation of counterweight assembly 949
Hydraulic system 951
Removal and installation of center swivel joint assembly 952
Disassembly and assembly of center swivel joint assembly 954
Removal and installation of hydraulic tank assembly . 955
Removal and installation of control valve assembly 957
Disassembly and assembly of control valve assembly 960
Removal and installation of hydraulic pump assembly . 964
Removal and installation of oil seal in hydraulic pump input shaft 967
Disassembly and assembly of work equipment PPC valve assembly . 968
Disassembly and assembly of travel PPC valve assembly . 970
Disassembly and assembly of hydraulic cylinder assembly . 973
Work equipment 981
Removal and installation of work equipment assembly . 982
Cab and its attachments . 987
Removal and installation of operator’s cab 988
Removal and installation of operator’s cab glass (stuck glass) 991
Removal and installation of front window assembly .1000
Electrical system .1007
Removal and installation of air conditioner unit assembly .1008
Removal and Installation of KOMTRAX terminal assembly .1010
Removal and installation of monitor assembly 1011
Removal and installation of pump controller .1012
90 Diagrams and drawings 0
Hydraulic diagrams and drawings .1015
Hydraulic circuit diagram .1017
Electrical diagrams and drawings 1020
Electrical circuit diagram 1022
Connector list and stereogram .1027

DESCRIPTION:

Komatsu PC400 -7E0,PC400LC-7E0,PC450 -7E0,PC450LC-7E0 Hydraulic Excavator Shop Manual SEN03578-05 – PDF DOWNLOAD

• SERIAL NUMBERS
  PC400/400LC- 60001-60089
  PC400/400LC- 65001 and up
  PC450/450LC- 30001-30058
  PC450/450LC- 65001 and up

G.B 26/12/24