Komatsu PC400-8 PC400LC-8 PC450-8 PC450LC-8 Excavator Shop Manual PDF

Description

Komatsu PC400-8 PC400LC-8 PC450-8 PC450LC-8 Excavator Shop Manual SEN02223-22 – PDF DOWNLOAD 

FILE DETAILS:

Komatsu PC400-8 PC400LC-8 PC450-8 PC450LC-8 Excavator Shop Manual SEN02223-22 – PDF DOWNLOAD

Language : English
Pages : 1150
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC400-8 PC400LC-8 PC450-8 PC450LC-8 Excavator Shop Manual SEN02223-22 – PDF DOWNLOAD 

SERIAL NUMBERS
PC400- 70001 and up
PC400LC- 70001 and up
PC450- 70001 and up
PC450LC- 70001 and up 

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)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu PC400-8 PC400LC-8 PC450-8 PC450LC-8 Excavator Shop Manual SEN02223-22 – PDF DOWNLOAD

SERIAL NUMBERS
PC400- 70001 and up
PC400LC- 70001 and up
PC450- 70001 and up
PC450LC- 70001 and up 

Cover 1
00 Index and foreword 3
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 57
Specification and technical data 57
Specification dimension drawings 58
Specifications 60
Weight table 64
Table of fuel, coolant and lubricants 68
10 Structure, function and maintenance standard 71
Engine and cooling system 71
Engine related parts 72
Radiator, oil cooler and aftercooler 73
Power train 75
Power train 76
Swing circle 77
Swing machinery 78
Final drive 80
Sprocket 82
Undercarriage and frame 85
Track frame and recoil spring 86
Idler 88
Carrier roller 90
Track roller 91
Track shoe 92
Hydraulic system, Part 1 97
Hydraulic equipment layout drawing 98
Hydraulic tank and filter 100
Hydraulic pump 102
Hydraulic system, Part 2 127
Control valve 128
CLSS 140
Functions and operation by valve 144
Merge-divider valve 159
Attachment circuit selector valve 184
Holding valve 186
Hydraulic system, Part 3 193
Valve control 194
PPC valve 196
Solenoid valve 212
PPC accumulator 214
Anti-drop valve for boom 216
Anti-drop valve for arm 222
Return oil filter 229
Center swivel joint 230
Travel motor 231
Swing motor 243
Hydraulic cylinder 252
Work equipment 255
Work equipment 256
Dimensions of components 258
Cab and its attachments 263
Air conditioner piping 264
Electrical system 267
Engine control 268
Electrical control system 279
Monitor system 304
Sensors 331
KOMTRAX terminal system 334
20 Standard value table 337
Standard service value table 337
Standard value table for engine 338
Standard value table for chassis related parts 339
Standard value table for chassis related parts (Loading shovel specification) 348
30 Testing and adjusting 359
Testing and adjusting, Part 1 359
Tools for testing, adjusting and troubleshooting 361
Sketches of special tools 365
Testing engine speed 366
Testing air boost pressure 367
Testing exhaust temperature 368
Testing exhaust gas color 369
Adjusting valve clearance 370
Testing compression pressure 372
Testing blow-by pressure 374
Testing engine oil pressure 375
Testing EGR valve drive pressure 376
Handling fuel system parts 377
Releasing residual pressure from fuel system 377
Testing fuel pressure 378
Handling during cylinder cut-out operation 379
Handling during no injection cranking operation 379
Testing fuel return and leakage 380
Bleeding air from fuel circuit 383
Checking fuel circuit for leakage 385
Checking and adjusting fan belt and alternator belt 386
Checking and adjusting air conditioner compressor belt tension 387
Testing swing circle bearing clearance 388
Checking and adjusting track shoe tension 389
Testing and adjustment oil pressure in work equipment, swing, and travel circuits 390
Testing control circuit basic pressure 394
Checking and adjusting pump PC control circuit oil pressure 395
Checking and adjusting pump LS control circuit oil pressure 398
Testing solenoid valve output pressure 403
Testing PPC valve output pressure 406
Adjusting play of work equipment and swing PPC valves 408
Inspecting locations of hydraulic drift of work equipment 409
Releasing residual pressure from hydraulic circuit 411
Testing oil leakage amount 412
Bleeding air from various parts 415
Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side) 418
Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side) 420
Replacing accumulator bladder on high pressure side for accumulator piping 422
Testing and adjusting, Part 2 429
Special functions of machine monitor 430
Testing and adjusting, Part 3 485
Handling voltage circuit of engine controller 486
Preparation work for troubleshooting of electrical system 487
Procedure for testing diodes 492
Pm Clinic service 493
Undercarriage troubleshooting report 500
40 Troubleshooting 503
Failure code table and fuse locations 503
Failure code table 504
Fuse locations 507
General Information on troubleshooting 513
Points to remember when troubleshooting 514
Sequence of events in troubleshooting 515
Check before troubleshooting 516
Classification and troubleshooting steps 517
Information in troubleshooting table 518
Possible problems and troubleshooting No 520
Connection table for connector pin numbers 522
T- branch box and T- branch adapter table 558
Troubleshooting by failure code, Part 1 563
Failure code [989L00] Engine Controller Lock Caution 1 565
Failure code [989M00] Engine Controller Lock Caution 2 566
Failure code [989N00] Engine Controller Lock Caution 3 567
Failure code [AA10NX] Air cleaner Clogging 568
Failure code [AB00KE] Charge Voltage Low 570
Failure code [B@BAZG] Eng Oil Press Low 572
Failure code [B@BAZK] Eng Oil Level Low 574
Failure code [B@BCNS] Eng Water Overheat 576
Failure code [B@BCZK] Eng Water Level Low 578
Failure code [B@HANS] Hydr Oil Overheat 580
Failure code [CA111] EMC Critical Internal Failure 581
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 583
Failure code [CA122] Chg Air Press Sensor High Error 584
Failure code [CA123] Chg Air Press Sensor Low Error 586
Failure code [CA131] Throttle Sensor High Error 588
Failure code [CA132] Throttle Sensor Low Error 590
Failure code [CA135] Eng Oil Press Sensor High Error 592
Failure code [CA141] Eng Oil Press Sensor Low Error 594
Failure code [CA144] Coolant Temp Sensor High Error 595
Failure code [CA145] Coolant Temp Sensor Low Error 597
Failure code [CA153] Chg Air Temp Sensor High Error 599
Failure code [CA154] Chg Air Temp Sensor Low Error 601
Failure code [CA187] Sens Supply 2 Volt Low Error 603
Failure code [CA221] Ambient Press Sens High Error 605
Failure code [CA222] Ambient Press Sens Low Error 607
Failure code [CA227] Sens Supply 2 Volt High Error 609
Failure code [CA234] Eng Overspeed 610
Failure code [CA238] Ne Speed Sens Supply Volt Error 611
Failure code [CA263] Fuel Temp Sensor High Error 612
Failure code [CA265] Fuel Temp Sensor Low Error 614
Failure code [CA271] IMV/PCV1 Short Error 615
Failure code [CA272] IMV/PCV1 Open Error 617
Failure code [CA273] PCV2 Short Error 619
Failure code [CA274] PCV2 Open Error 621
Failure code [CA322] Inj #1 Open/Short Error 623
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error 625
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error 627
Failure code [CA325] Inj #6 Open/Short Error 629
Failure code [CA331] Inj #2 Open/Short Error 631
Failure code [CA332] Inj #4 Open/Short Error 633
Troubleshooting by failure code, Part 2 637
Failure code [CA342] Calibration Code Incompatibility 639
Failure code [CA351] Injectors Drive Circuit Error 640
Failure code [CA352] Sens Supply 1 Volt Low Error 642
Failure code [CA386] Sens Supply 1 Volt High Error 644
Failure code [CA441] Battery Voltage Low Error 646
Failure code [CA442] Battery Voltage High Error 648
Failure code [CA449] Rail Press Very High Error 650
Failure code [CA451] Rail Press Sensor High Error 653
Failure code [CA452] Rail Press Sensor Low Error 655
Failure code [CA553] Rail Press High Error 657
Failure code [CA554] Rail Press Sensor In Range Error 658
Failure code [CA559] Rail Press Low Error 659
Failure code [CA689] Eng Ne Speed Sensor Error 663
Failure code [CA731] Eng Bkup Speed Sens Phase Error 665
Failure code [CA757] All Continuous Data Lost Error 666
Failure code [CA778] Eng Bkup Speed Sensor Error 668
Failure code [CA1228] EGR valve servo error 1 670
Failure code [CA1625] EGR valve servo error 2 671
Failure code [CA1633] KOMNET Datalink Timeout Error 672
Failure code [CA2185] Throt Sens Sup Volt High Error 674
Failure code [CA2186] Throt Sens Sup Volt Low Error 676
Failure code [CA2249] Rail Press Very Low Error 677
Failure code [CA2271] EGR valve lift sensor high error 678
Failure code [CA2272] EGR valve lift sensor low error 680
Failure code [CA2351] EGR valve solenoid operation short circuit 681
Failure code [CA2352] EGR valve solenoid operation disconnect 683
Failure code [CA2555] Grid Htr Relay Volt Low Error 684
Failure code [CA2556] Grid Htr Relay Volt High Error 686
Failure code [D110KB] Battery Relay Drive S/C 688
Failure code [D19JKZ] Personal Code Relay Abnormality 690
Failure code [D862KA] GPS Antenna Discon 692
Failure code [DA22KK] Pump Solenoid Power Low Error 693
Failure code [DA25KP] 5V sensor power supply output 1 abnormality 695
Failure code [DA29KQ] Model Selection Abnormality 698
Troubleshooting by failure code, Part 3 701
Failure code [DA2RMC] CAN Discon (Pump con detected) 703
Failure code [DAF8KB] Short circuit in camera power supply 705
Failure code [DAFGMC] GPS Module Error 707
Failure code [DAFRMC] CAN discon (Monitor detected) 708
Failure code [DGH2KB] Hyd Oil Sensor Short 710
Failure code [DHPAMA] F Pump Press Sensor Abnormality 711
Failure code [DHPBMA] R Pump Press Sensor Abnormality 713
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 715
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 717
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) 719
Failure code [DW43KA] Travel Speed Sol Open Circuit 720
Failure code [DW43KB] Travel Speed Sol Short Circuit 722
Failure code [DW45KA] Swing Brake Sol Open Circuit 724
Failure code [DW45KB] Swing Brake Sol Short Circuit 726
Failure code [DW91KA] Travel Junction Sol Open Circuit 728
Failure code [DW91KB] Travel Junction Sol Short Circuit 730
Failure code [DWA2KA] Attachment Sol Open Circuit 732
Failure code [DWA2KB] Attachment Sol Short Circuit 733
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 734
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 736
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 738
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 740
Failure code [DXA0KA] PC-EPC Sol Open Circuit 742
Failure code [DXA0KB] PC-EPC Sol Short Circuit 744
Failure code [DXE0KA] LS-EPC Sol Open Circuit 746
Failure code [DXE0KB] LS-EPC Sol Short Circuit 748
Failure code [DXE4KA] Service Current EPC Open Circuit 750
Failure code [DXE4KB] Service Current EPC Short Circuit 751
Failure code [DY20KA] Wiper Working Abnormality 752
Failure code [DY20MA] Wiper Parking Abnormality 754
Failure code [DY2CKA] Washer Drive Open Discon 756
Failure code [DY2CKB] Washer Drive Short Circuit 758
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 760
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 762
Troubleshooting of electrical system (E-mode) 765
Before carrying out troubleshooting of electrical system 768
Information contained in troubleshooting table 770
E-1 Engine does not start 771
E-2 Auto-decelerator does not operate 774
E-3 Automatic warming-up system does not operate 776
E-4 Preheater does not operate 778
E-5 All work equipment, swing, and travel mechanism do not move 780
E-6 Power maximizing function does not operate 782
E-7 Machine monitor does not display at all 784
E-8 Machine monitor does not display some items 786
E-9 Contents of display by machine monitor are different from applicable machine 786
E-10 Fuel level monitor was lighted in red while engine running 787
E-11 Engine coolant temperature gauge does not indicate normally 788
E-12 Hydraulic oil temperature gauge does not indicate normally 790
E-13 Fuel level gauge does not indicate normally 791
E-14 Swing lock monitor does not indicate normally 792
E-15 When monitor switch is operated, monitor displays nothing 794
E-16 Windshield wiper and window washer do not operate 796
E-17 Machine push-up function does not operate normally 800
E-18 Monitoring function fails to display “boom raise” normally 802
E-19 Monitoring function fails to display “boom lower” normally 804
E-20 Monitoring function fails to display “arm IN” normally 806
E-21 Monitoring function fails to display “arm OUT” normally 808
E-22 Monitoring function fails to display “bucket CURL” normally 810
E-23 Monitoring function fails to display “bucket DUMP” normally 812
E-24 Monitoring function fails to display “swing” normally 814
E-25 Monitoring function fails to display “travel” normally 816
E-26 Monitoring function fails to display “travel differential pressure” normally 818
E-27 Monitoring function fails to display “service” normally 820
E-28 KOMTRAX system does not operate normally 822
E-29 Air conditioner does not operate 824
E-30 Travel alarm does not sound or does not stop sounding 826
E-31 Horn does not sound 828
Troubleshooting of hydraulic and mechanical system (H-mode) 831
System chart for hydraulic and mechanical system 834
Information contained in troubleshooting table 836
H-1 All work equipment lack power, or travel and swing speeds are slow 838
H-2 Engine speed sharply drops or engine stalls 840
H-3 No work equipment, swing or travel move 841
H-4 Abnormal noise is heard from around hydraulic pump 841
H-5 Auto-decelerator does not work 842
H-6 Fine control mode does not function or responds slow 842
H-7 Boom moves slowly or lacks power 843
H-8 Arm moves slowly or lacks power 844
H-9 Bucket moves slowly or lacks power 845
H-10 Work equipment does not move in its single operation 845
H-11 Work equipment has a bit too fast hydraulic drift 846
H-12 Work equipment has big time lag 848
H-13 Other work equipment moves when relieving single circuit 848
H-14 Power max switch does not operate 848
H-15 Machine push-up function does not operate 849
H-16 In compound operation of work equipment, speed of part loaded more is low 850
H-17 When machine swings and raises boom simultaneously, boom rising speed is low 850
H-18 When machine swings and travels simultaneously, travel speed lowers largely 850
H-19 Machine deviates during travel 851
H-20 Travel speed is low 852
H-21 Machine is not steered well or steering power is low 853
H-22 Travel speed does not change or travel speed is low or high 854
H-23 Travel system does not move (only one side) 855
H-24 Upper structure does not swing 856
H-25 Swing acceleration or swing speed is low 858
H-26 Upper structure overruns remarkably when it stops swinging 860
H-27 Large shock is made when upper structure stops swinging 861
H-28 Large sound is made when upper structure stops swinging 861
H-29 Hydraulic drift of swing is large 862
H-30 Attachment circuit is not changed 863
H-31 Oil flow in attachment circuit cannot be controlled 863
Troubleshooting of engine (S-mode) 865
Method of using troubleshooting chart 867
S-1 Starting performance is poor 870
S-2 Engine does not start 872
S-3 Engine does not pick up smoothly 876
S-4 Engine stops during operations 877
S-5 Engine does not rotate smoothly 878
S-6 Engine lacks output (or lacks power) 879
S-7 Exhaust smoke is black (incomplete combustion) 880
S-8 Oil consumption is excessive (or exhaust smoke is blue) 881
S-9 Oil becomes contaminated quickly 882
S-10 Fuel consumption is excessive 883
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 884
S-12 Oil pressure drops 885
S-13 Oil level rises (Entry of coolant or fuel) 886
S-14 Coolant temperature becomes too high (overheating) 888
S-15 Abnormal noise is made 889
S-16 Vibration is excessive 890
50 Disassembly and assembly 893
General information on disassembly andassembly 893
How to read this manual 894
Coating materials list 896
Special tool list 899
Sketches of special tools 902
Engine and cooling system 909
Removal and installation of fuel supply pump assembly 910
Removal and installation of fuel injector assembly 914
Removal and installation of engine front seal 920
Removal and installation of engine rear seal 923
Removal and installation of cylinder head assembly 928
Removal and installation of radiator assembly 937
Removal and installation of hydraulic oil cooler assembly 939
Removal and installation of aftercooler assembly 941
Removal and installation of engine and hydraulic oil pump assembly 942
Power train 951
Removal and installation of travel motor and final drive assembly 952
Disassembly and assembly of final drive assembly 953
Removal and installation of swing motor and swing machinery assembly 962
Disassembly and assembly of swing motor and swing machinery assembly 963
Removal and installation of swing circle assembly 970
Undercarriage and frame 973
Disassembly and assembly of carrier roller assembly 974
Disassembly and assembly of track roller assembly 976
Disassembly and assembly of idler assembly 977
Disassembly and assembly of recoil spring assembly 980
Removal and installation of sprocket 982
Expansion and installation of track shoe assembly 983
Removal and installation of revolving frame assembly 985
Removal and installation of counterweight assembly 988
Hydraulic system 993
Removal and installation of center swivel joint assembly 994
Disassembly and assembly of center swivel joint assembly 996
Removal and installation of hydraulic tank assembly 997
Removal and installation of control valve assembly 999
Disassembly and assembly of control valve assembly 1002
Removal and installation of hydraulic pump assembly 1006
Removal and installation of oil seal in hydraulic pump input shaft 1009
Disassembly and assembly of work equipment PPC valve assembly 1010
Disassembly and assembly of travel PPC valve assembly 1012
Disassembly and assembly of hydraulic cylinder assembly 1015
Work equipment 1023
Removal and installation of work equipment assembly 1024
Removal and installation of anti- drop valve assembly for boom 1027
Removal and installation of anti- drop valve assembly for arm 1030
Disassembly and assembly of anti-drop valve assembly 1032
Cab and its attachments 1035
Removal and installation of operator cab assembly 1036
Removal and installation of operator cab glass (stuck glass) 1039
Removal and installation of front window assembly 1049
Removal and installation of floor frame assembly 1056
Removal and installation of work equipment control lever assembly 1060
Electrical system 1075
Removal and installation of air conditioner unit assembly 1076
Removal and installation of KOMTRAX communication modem assembly 1079
Removal and installation of monitor assembly 1080
Removal and installation of pump controller assembly 1082
Removal and installation of engine controller 1084
80 Appendix 1087
Combustion-type heater 1087
Handling combustion-type heater 1088
Overall layout of preheating device and flow of engine coolant 1089
Structure and function of combustion-type heater 1091
Electrical circuit diagram 1093
Operation and function 1094
Overheat prevention function 1095
Troubleshooting and repair instructions 1096
Electrical circuit diagram of combustion-type heater 1127
90 Diagrams and drawings 1129
Hydraulic diagrams and drawings 1129
Hydraulic circuit diagram 1131
Electrical diagrams and drawings 1135
Electrical circuit diagram 1137
Connector list and stereogram 1147

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S.V  17/12/24