Komatsu PC400 PC400LC-7 PC450-7 PC450LC-7 Shop Manual SEBM033005 – PDF DOWNLOAD

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Komatsu PC400 PC400LC-7 PC450-7 PC450LC-7 Shop Manual SEBM033005 – PDF DOWNLOAD

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Komatsu PC400 PC400LC-7 PC450-7 PC450LC-7 Shop Manual SEBM033005 – PDF DOWNLOAD

Language : English
Pages :785
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC400 PC400LC-7 PC450-7 PC450LC-7 Shop Manual SEBM033005 – PDF DOWNLOAD

MACHINE MODEL       SERIAL No.
PC400-7                    50001 and up
PC400LC-7                  50001 and up
PC450-7                      20001 and up
PC450LC-7              20001 and up

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 PC400LC-7 PC450-7 PC450LC-7 Shop Manual SEBM033005 – PDF DOWNLOAD

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 8
SAFETY NOTICE 8
FOREWORD 10
GENERAL 10
HOW TO READ THE SHOP MANUAL 11
HOISTING INSTRUCTIONS 12
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 13
COATING MATERIALS 15
STANDARD TIGHTENING TORQUE 17
ELECTRIC WIRE CODE 20
CONVERSION TABLE 21
UNITS 27
01 GENERAL 28
SPECIFICATION DRAWINGS 29
SPECIFICATIONS 31
WEIGHT TABLE 35
FUEL, COOLANT AND LUBRICANTS 39
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 40
ENGINE RELATED PARTS 41
RADIATOR•OIL COOLER•AFTERCOOLER 42
POWER TRAIN 43
FINAL DRIVE 45
SPROCKET 47
SWING MACHINERY 49
SWING CIRCLE 51
TRACK FRAME AND RECOIL SPRING 53
IDLER 55
CARRIER ROLLER 57
TRACK ROLLER 58
TRACK SHOE 59
HYDRAULIC PIPING DRAWING 63
HYDRAULIC TANK 65
HYDRAULIC PUMP 67
LS(PC)-EPC VALVE 85
VARIABLE VOLUME VALVE 88
CONTROL VALVE 91
MAIN RELIEF VALVE105
CLSS107
SELF PRESSURE REDUCING VALVE110
SWING MOTOR113
CENTER SWIVEL JOINT121
TRAVEL MOTOR123
TRAVEL JUNCTION VALVE134
VALVE CONTROL136
TRAVEL PPC SHUTTLE VALVE137
WORK EQUIPMENT • SWING PPC VALVE141
TRAVEL PPC VALVE145
SERVICE PPC VALVE152
SOLENOID VALVE153
PPC ACCUMULATOR155
RETURN OIL FILTER156
BOOM HYDRAULIC DRIFT PREVENTION VALVE157
ARM HYDRAULIC DRIFT PREVENTION VALVE162
QUICK RETURN VALVE166
LIFT CHECK VALVE168
ATTACHMENT CIRCUIT SELECTOR VALVE169
HOLDING VALVE171
HYDRAULIC CYLINDER177
WORK EQUIPMENT179
AIR CONDITIONER185
ENGINE CONTROL186
ELECTRONIC CONTROL SYSTEM192
MONITOR SYSTEM219
7-SEGMENT MONITOR SYSTEM239
SENSOR246
20 TESTING AND ADJUSTING249
STANDARD VALUE TABLE FOR ENGINE250
STANDARD VALUE TABLE FOR CHASSIS251
TESTING AND ADJUSTING261
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE262
MEASURING ENGINE SPEED264
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)265
MEASURING EXHAUST TEMPERATURE266
MEASURING EXHAUST GAS COLOR267
ADJUSTING VALVE CLEARANCE268
MEASURING COMPRESSION PRESSURE270
MEASURING BLOW-BY PRESSURE272
MESURING ENGINE OIL PRESSURE273
HANDLING OF FUEL SYSTEM DEVICES274
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM274
MEASURING FUEL PRESSURE275
BLEEDING AIR FROM FUEL CIRCUIT276
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE278
ADJUSTING ENGINE SPEED SENSOR279
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION280
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION281
MEASURING CLEARANCE OF SWING CIRCLE BEARING282
TESTING AND ADJUSTING TRACK SHOE TENSION283
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS284
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT288
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT289
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT292
MEASURING SOLENOID VALVE OUTPUT PRESSURE297
MEASURING PPC VALVE OUTPUT PRESSURE300
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES302
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT303
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT305
MEASURING OIL LEAKAGE306
BLEEDING AIR FROM EACH PART309
TESTING PROCEDURE OF DIODE312
SPECIAL FUNCTIONS OF MONITOR PANEL313
HANDLING OF HIGH VOLTAGE CIRCUIT OF ENGINE CONTROLLER340
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM341
PM CLINIC SERVICE343
TROUBLESHOOTING351
POINTS TO REMEMBER WHEN TROUBLESHOOTING352
SEQUENCE OF EVENTS IN TROUBLESHOOTING353
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE354
CHECKS BEFORE TROUBLESHOOTING362
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING363
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM367
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS384
T-BRANCH BOX AND T-BRANCH TABLE406
TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISPLAYED409
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE412
Error Code in Electrical System [E112] (Short-circuiting in normal rotation system of windshield wiper motor drive)414
Error Code in Electrical System [E113] (Short-circuiting in reverse rotation system of windshield wiper motor drive)416
Error Code in Electrical System [E114] (Short-circuiting in window washer drive system)418
Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion)420
Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper)422
Error Code in Electrical System [E117] (Eng Controller S-NET Comm Err) 424
Error Code in Electrical System [E118] (Pump Controller S-NET Comm Err) 426
Error Code in Electrical System [E128] (Monitor Comm Abnormality)428
Error Code in Electrical System [E201] (Short-circuiting in travel interlocking solenoid)430
Error Code in Electrical System [E203] (Short-circuiting in swing holding brake solenoid)432
Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid)434
Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid)435
Error Code in Electrical System [E206] (Short-circuiting in travel speed shifting solenoid)436
Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid)437
Error Code in Electrical System [E213] (Disconnection in swing holding brake solenoid)438
Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)440
Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)441
Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid)442
Error Code in Electrical System [E217] (Abnormal input model code) 444
Error Code in Electrical System [E218] (S-Net Comm Disc) 446
Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid)448
Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system)449
Error Code in Electrical System [E224] (F Pump P Sensor Abnormality) 450
Error Code in Electrical System [E225] (R Pump P Sensor Abnormality)452
Error Code in Electrical System [E226] (Press Sensor Power Abnormality)454
Error Code in Electrical System [E227] (Abnormality in engine rotation sensor)456
Error Code in Electrical System [E228] (Short-circuiting in attachment return switching relay)457
Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid)458
Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)460
Error Code in Electrical System [E238] (Disconnection in attachment return switching relay)462
Error Code in Electrical System [E245] (Short-circuiting in attachment oil flow rate adjusting EPC)464
Error Code in Electrical System [E246] (Disconnection in attachment oil flow rate adjusting EPC)465
Error Code in Electrical System [E247] (Arm IN PPC pressure sensor abnormality)466
Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)468
Error Code in Electrical System [E257] (Pump Abnormality)470
Error Code in Electrical System [E315] (Battery Relay Drive S/C) 472
Error Code in Electrical System [E91B] (Engine Ne sensor problem)474
Error Code in Electrical System [E91C] (Engine G sensor problem)475
Error Code in Electrical System [E920] (Engine type selection error)476
Error Code in Electrical System [E921] (Engine type mismatch)478
Error Code in Electrical System [E931] (Fuel dial sys error)480
Error Code in Electrical System [E934] (Engine coolant sensor Hi error)482
Error Code in Electrical System [E936] (Engine oil press sw error)484
Error Code in Electrical System [E93C] (Engine boost sensor error)486
Error Code in Electrical System [E93D] (Engine fuel temp sensor error)488
Error Code in Electrical System [E953] (Engine Comm Abnormality)490
Error Code in Electrical System [E954] (Short engine starter sw)492
Error Code in Electrical System [E955] (Engine S-NET error)494
Error Code in Electrical System [E956] (Engine power failure (1))496
Error Code in Electrical System [E957] (Engine power failure (2))498
Error Code in Electrical System [E95A] (Engine Q-adj sw signal error) 500
Error Code in Electrical System [E96A] (Engine coolant sensor Lo error) 502
Error Code in Electrical System [E970] (PCV1 over current)504
Error Code in Electrical System [E971] (PCV2 over current)505
Error Code in Electrical System [E974] (PCV1 line cut)506
Error Code in Electrical System [E975] (PCV2 line cut)507
Error Code in Electrical System [E977] (Rail press sensor error)508
Error Code in Electrical System [E979] (Rail press high)510
Error Code in Electrical System [E97A] (Rail press abnormal)510
Error Code in Electrical System [E97B] (Rail press low)511
Error Code in Electrical System [E97C] (Rail press too low)513
Error Code in Electrical System [E97D] (Rail press out of control)513
Error Code in Electrical System [E980] (Eng Controller Abnormality)514
Error Code in Electrical System [E981] (Fuel Injector 1 Disc)516
Error Code in Electrical System [E982] (Fuel Injector 2 Disc) 517
Error Code in Electrical System [E983] (Fuel Injector 3 Disc)518
Error Code in Electrical System [E984] (Fuel Injector 4 Disc)519
Error Code in Electrical System [E985] (Fuel Injector 5 Disc)520
Error Code in Electrical System [E986] (Fuel Injector 6 Disc)521
Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C)522
Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C)524
Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)526
Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard)526
Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging)528
Failure Code in Mechanical System [AB00KE] (Charge Voltage Low)530
Failure Code in Mechanical System [B@BAZG] (Eng Oil Press Low)532
Failure Code in Mechanical System [B@BAZK] (Eng Oil Level Low)534
Failure Code in Mechanical System [B@BCNS] (Eng Water Overheat)535
Failure Code in Mechanical System [B@BCZK] (Eng Water Lvl Low)536
Failure Code in Mechanical System [B@HANS] (Hydr Oil Overheat)537
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)539
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE541
E-1 The engine does not start (The engine does not rotate)542
E-2 Preheater does not operate546
E-3 Auto engine warm-up device does not work548
E-4 Auto-decelerator does not operate549
E-5 All work equipment, swing and travel do not move550
E-6 One-touch power max function does not operate552
E-7 Machine push-up function does not operate normally553
E-8 Attachment circuit does not change555
E-9 No display in monitor panel at all557
E-10 Part of display on monitor panel is missing558
E-11 Monitor panel displays contents irrelevant to the model558
E-12 Fuel level monitor red lamp lights up while engine is running559
E-13 Engine water temperature gauge does not display correctly560
E-14 Hydraulic oil temperature gauge does not display correctly562
E-15 Fuel gauge does not display correctly563
E-16 Swing lock monitor does not display correctly564
E-17 When monitor switch is operated, nothing is displayed566
E-18 Windshield wiper and window washer do not work568
E-19 Alarm buzzer cannot be cancelled572
E-20 “Boom RAISE” is not correctly displayed in monitor function573
E-21 “Boom LOWER” is not correctly displayed in monitor function574
E-22 “Arm IN” is not displayed normally in monitoring function575
E-23 “Arm DUMPING” is not correctly displayed in monitor function576
E-24 “Bucket CURL” is not displayed normally in monitoring function577
E-25 “Bucket DUMPING” is not correctly displayed in monitor function578
E-26 “Swing” is not displayed normally in monitoring function580
E-27 “TRAVEL” is not correctly displayed in monitor function582
E-28 “Travel Differential Pressure” is not correctly displayed in monitor function584
E-29 “Service” is not correctly displayed in monitor function586
E-30 Travel alarm does not sound or does not stop sounding588
E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM590
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)601
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM602
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE604
H-1 All work equipment lack power, or travel and swing speeds are slow605
H-2 Engine speed sharply drops or engine stalls606
H-3 No work equipment, travel or swing move607
H-4 Abnormal noise is heard from around hydraulic pump607
H-5 Auto-decelerator does not work608
H-6 Fine control mode does not function608
H-7 Boom moves slowly or lacks power609
H-8 Arm moves slowly or lacks power610
H-9 Bucket moves slowly or lacks power611
H-10 Work equipment does not move in its single operation611
H-11 Work equipment has a bit too fast hydraulic drift612
H-12 Work equipment has big time lag613
H-13 Other work equipment moves when relieving single circuit613
H-14 One-touch power max function does not work613
H-15 Machine push-up function does not work614
H-16 In compound operation, work equipment with larger load moves slowly615
H-17 In swing + boom RAISE operation, boom moves slowly615
H-18 In swing + travel, travel speed drops sharply615
H-19 Machine swerves in travel616
H-20 Machine travels slowly617
H-21 Machine cannot be easily steered or lacks power618
H-22 Travel speed does not shift, or it is slower or faster than preset speed619
H-23 Track shoe does not turn (on one side only)620
H-24 Machine does not swing621
H-25 Swing acceleration is poor, or swing speed is slow622
H-26 Excessive overrun when stopping swing623
H-27 There is big shock when stopping swing624
H-28 There is big abnormal noise caused when stopping swing624
H-29 Swing natural drift is too big625
H-30 Attachment circuit does not change626
H-31 Flow rate in attachment circuit cannot be adjusted626
TROUBLESHOOTING OF ENGINE (S MODE)627
POINTS TO REMEMBER WHEN TROUBLESHOOTING628
METHOD OF USING TROUBLESHOOTING CHARTS629
S-1 Starting performance is poor (starting always takes time)632
S-2 Engine does not start633
S-3 Engine does not pick up smoothly (follow-up is poor)636
S-4 Engine stops during operations637
S-5 Engine does not rotate smoothly (hunting)638
S-6 Engine lacks output (or lacks power)639
S-7 Exhaust smoke is black (incomplete combustion)640
S-8 Oil consumption is excessive (or exhaust smoke is blue)641
S-9 Oil becomes contaminated quickly642
S-10 Fuel consumption is excessive643
S-11 Oil is in cooling water (or water spurts back, or water level goes down)644
S-12 Oil pressure caution lamp lights up (drop in oil pressure)645
S-13 Oil level rises (water, fuel in oil)646
S-14 Water temperature becomes too high (overheating)647
S-15 Abnormal noise is made648
S-16 Vibration is excessive649
30 DISASSEMBLY AND ASSEMBLY650
HOW TO READ THIS MANUAL651
PRECAUTIONS WHEN PERFORMING OPERATION653
SPECIAL TOOL LIST655
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY663
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL670
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL674
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY677
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY680
REMOVAL AND INSTALLATION OF NOZZLE TIP683
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY685
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY686
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY688
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY690
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY695
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY696
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY697
REMOVAL AND INSTALLATION OF SPROCKET704
REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY705
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY706
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY713
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY715
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY716
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY719
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY721
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY723
REMOVAL AND INSTALLATION OF OPERATOR’S CAB725
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY728
REMOVAL AND INSTALLATION OF PUMP CONTROLLER729
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER730
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY731
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY734
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY735
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY737
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT740
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY741
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY744
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY748
DISASSEMBLY AND ASSEMBLY OF OF CENTER SWIVEL JOINT ASSEMBLY750
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY751
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY752
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY753
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY758
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)761
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY771
90 OTHERS777
HYDRAULIC CIRCUIT DIAGRAM (1/2)778
HYDRAULIC CIRCUIT DIAGRAM (2/2)779
ELECTRICAL CIRCUIT DIAGRAM (1/5)780
ELECTRICAL CIRCUIT DIAGRAM (2/5)781
ELECTRICAL CIRCUIT DIAGRAM (3/5) 782
ELECTRICAL CIRCUIT DIAGRAM (4/5)783
ELECTRICAL CIRCUIT DIAGRAM (5/5)784
AIR CONDITIONER ELECTRICAL CIRCUIT785

IMAGES PREVIEW OF THE MANUAL:

S.M 12/12/24