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KOMATSU PC400LC-6 PC400HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (A80001 and up) – PDF Download
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- KOMATSU PC400LC-6 PC400HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (Sn:A80001 and up)
- PUBLICATION NUMBER:CEBM4006C3
- SERIAL NUMBERS PC400HD-6 – A80001 & Up
PC4OOLC-6 – A80001 & Up
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Description
KOMATSU PC400LC-6 PC400HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (Sn:A80001 and up)
KOMATSU PC400LC-6 PC400HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (A80001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC400LC-6 PC400HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (Sn:A80001 and up)
- 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 sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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. - 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” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU PC400LC-6 PC400HD-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (Sn:A80001 and up)
MAIN MENU........................................................................................................................................... 0 CONTENTS............................................................................................................................................ 2 01 GENERAL.......................................................................................................................................... 24 SPECIFICATION DRAWINGS.......................................................................................................................... 25 SPECIFICATIONS.................................................................................................................................. 29 WEIGHT TABLE.................................................................................................................................... 31 FUEL, COOLANT AND LUBRICANTS.................................................................................................................... 33 ENGINE OIL SPECIFICATIONS....................................................................................................................... 36 DIESEL FUEL SPECIFICATIONS...................................................................................................................... 37 COOLANT SPECIFICATIONS.......................................................................................................................... 38 10 STRUCTURE AND FUNCTION........................................................................................................................... 42 PARTS RELATED TO ENGINE......................................................................................................................... 43 RADIATOR, OIL COOLER............................................................................................................................ 45 POWER TRAIN..................................................................................................................................... 46 FINAL DRIVE..................................................................................................................................... 47 SWING CIRCLE.................................................................................................................................... 48 SWING MACHINERY................................................................................................................................. 49 TRACK FRAME, RECOIL SPRING - PC400LCC-6......................................................................................................... 50 TRACK FRAME, RECOIL SPRING FOLDOUT - PC400HD-6.................................................................................................. 51 TRACK SHOE...................................................................................................................................... 52 HYDRAULIC PIPING DRAWING........................................................................................................................ 53 HYDRAULIC CIRCUIT DRAWING....................................................................................................................... 54 HYDRAULIC TANK, HYDRAULIC FILTER................................................................................................................ 55 HYDRAULIC PUMP.................................................................................................................................. 56 CONTROL VALVE................................................................................................................................... 77 SUCTION SAFETY VALVE............................................................................................................................ 86 CLSS............................................................................................................................................ 87 SWING MOTOR.....................................................................................................................................120 CENTER SWIVEL JOINT.............................................................................................................................124 TRAVEL MOTOR....................................................................................................................................125 VALVE CONTROL...................................................................................................................................134 WORK EQUIPMENT, SWING PPC VALVE.................................................................................................................135 TRAVEL PPC VALVE................................................................................................................................139 SERVICE PPC VALVE...............................................................................................................................143 PPC SAFETY LOCK VALVE...........................................................................................................................146 PCC ACCUMULATOR.................................................................................................................................146 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE........................................................................................................147 EPC SOLENOID VALVE..............................................................................................................................154 BOOM HOLDING VALVE..............................................................................................................................159 HYDRAULIC CYLINDER..............................................................................................................................162 WORK EQUIPMENT..................................................................................................................................163 ACTUAL ELECTRIC WIRING DIAGRAM..................................................................................................................164 ELECTICAL CIRCUIT DIAGRAM.......................................................................................................................174 ENGINE CONTROL..................................................................................................................................177 ELECTRICAL CONTROL SYSTEM.......................................................................................................................184 MACHINE MONITOR SYSTEM..........................................................................................................................207 20 TESTING AND ADJUSTMENT...........................................................................................................................214 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................215 STANDARD VALUE TABLE FOR CHASSIS PARTS..........................................................................................................216 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.......................................................................................................224 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING................................................................................................232 MEASURING ENGINE SPEED..........................................................................................................................233 MEASURING INTAKE MANIFOLD PRESSURE..............................................................................................................234 MEASURING INTAKE AIR RESTRICTION................................................................................................................234 MEASURING LUBRICATING OIL PRESSURE..............................................................................................................234 MEASURING FUEL (FILTER) INLET RESTRICTION.......................................................................................................234 MEASURING BLOWBY PRESSURE.......................................................................................................................235 MEASURING ENGINE BACK PRESSURE..................................................................................................................235 MEASURING EXHAUST COLOR.........................................................................................................................235 MEASURING COOLANT TEMPERATURE...................................................................................................................236 MEASURING VALVE CLEARANCE.......................................................................................................................236 BELT TENSION....................................................................................................................................237 GOVERNOR MOTOR LEVER STROKE.....................................................................................................................238 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................................................239 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...................................................................242 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTAIL PRESSURE.......................................244 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE.........................................................................................247 TESTING SOLENOID VALVE OUTPUT PRESSURE..........................................................................................................249 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...............................................................................251 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.......................................................................................................253 TESTING TRAVEL DEVIATION........................................................................................................................254 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................................................255 MEASURING OIL LEAKAGE...........................................................................................................................257 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................259 TESTING CLEARANCE OF SWING CIRCLE BEARING.......................................................................................................260 TESTING AND ADJUSTING TRACK SHOE TENSION........................................................................................................261 BLEEDING AIR....................................................................................................................................262 TROUBLESHOOTING.................................................................................................................................264 POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................................................265 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................................................266 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................................................267 CHECKS BEFORE TROUBLESHOOTING...............................................................................................................276 CONNECTOR TYPES AND MOUNTING LOCATIONS......................................................................................................277 CONNECTOR ARRANGEMENT DIAGRAM...............................................................................................................281 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................................................290 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM......................................................................................301 DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL.....................................................................................302 METHOD OF USING JUDGEMENT TABLE.............................................................................................................310 METHOD OF USING TROUBLESHOOTING CHARTS......................................................................................................312 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE....................................................................................314 SERVICE CODE TABLE..........................................................................................................................319 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)................................................................................320 N-1 [E218] Communication abnormality....................................................................................................321 TROUBLESHOOTING OF GOVERNOR PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)..............................................................323 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM................................................324 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.............................................................325 JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND RELATED PARTS.................................................329 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM............................................................................................331 E-1 Abnormality in governor, pump controller power source (controller LED is OFF)...................................................333 E-2 [E308] Abnormality in fuel control dial input value is displayed................................................................334 E-3 [317] Abnormality (disconnection) in motor drive system is displayed............................................................335 E-4 [318] Abnormality (short circuit) in motor drive system is displayed............................................................336 E-5 [E306] Abnormality in feedback potentiometer system is displayed................................................................337 E-6 [E315] Abnormality (short circuit) in battery relay output system is displayed..................................................338 E-7 [E316] Abnormality (step-out) in motor displayed................................................................................339 E-8 Engine does not start...........................................................................................................340 E-9 Engine speed is irregular.......................................................................................................342 E-10 Lack of output (engine high idling speed is to low)............................................................................346 E-11 Engine does not stop...........................................................................................................348 E-12 Defective operation of battery relay system (engine does not stop).............................................................350 TROUBLESHOOTING OF ENGINE SYSTEM............................................................................................................352 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................................353 S-1 Starting performance is poor (starting always takes time)...........................................................................357 S-2 Engine does not start...............................................................................................................358 S-3 Engine does not pick up smoothly (follow up is poor)................................................................................361 S-4 Engine stops during operations......................................................................................................362 S-5 Engine does not rotate smoothly (hunting)...........................................................................................363 S-6 Engine lacks output (no power)......................................................................................................364 S-7 Engine smoke is black (incomplete combustion).......................................................................................365 S-8 Oil consumption is excessive (or exhaust smoke is blue).............................................................................366 S-9 Oil becomes contaminated quickly....................................................................................................366 S-10 Fuel consumption is excessive......................................................................................................366 S-11 Oil is in cooling water, or water spurts back, or water level goes down............................................................366 S-12 Oil pressure caution lamp lights up (drop in oil pressure).........................................................................366 S-13 Oil level rises (water, fuel in oil)...............................................................................................367 S-14 Water temperature becomes too high (overheating)...................................................................................368 S-15 Abnormal noise is made.............................................................................................................369 S-16 Vibration is excessive.............................................................................................................370 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM (C MODE)..................................................................371 POINT TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...........................................................................372 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..............................................................373 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.........................................379 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE...................................................................................................381 C-1 Abnormality in controller power source system (controller LED is OFF)...........................................................383 C-2 [E232] Short Circuit in front pump TVC solenoid system is displayed.............................................................384 C-3 [E233] Disconnection in front pump TVC solenoid system is displayed.............................................................386 C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed..............................................................388 C-5 [E237] Disconnection in rear pump TVC solenoid system is displayed..............................................................390 C-6 [E202] Short circuit in LS select solenoid system is displayed..................................................................392 C-7 [E212] Disconnection in LS select solenoid system is displayed..................................................................393 C-8 [E203[ Short circuit in swing brake solenoid system is displayed................................................................394 C-9 [E213] Disconnection in swing brake solenoid system is displayed................................................................396 C-10 [E204] Short circuit in pump merge/divider solenoid system is displayed........................................................398 C-11 [E214] Disconnection in pump merge/divider solenoid system is displayed........................................................399 C-12 [E206] Short circuit in travel speed solenoid system is displayed..............................................................400 C-13 [E216] Disconnection in travel speed selector solenoid system is displayed.....................................................401 C-14 [E217] Model selection input error is displayed................................................................................402 C-15 [E222] Short circuit in LS-EPC solenoid system is displayed....................................................................404 C-16 [E223] Disconnection in LS-EPC solenoid system is displayed....................................................................405 C-17 [E224] Abnormality in front pump pressure sensor system is displayed...........................................................406 C-18 [E225] Abnormality in rear pump pressure sensor system is displayed............................................................407 C-19 [E226] Abnormality in pressure sensor power source system is displayed.........................................................408 C-20 [E227] Abnormality in engine speed sensor system is displayed..................................................................409 C-21 Abnormality in machine push up solenoid system (no service code is displayed...................................................410 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)................................................................412 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE...................................................................................................413 F-1 Bit pattern 20-(1) Swing oil pressure switch does not light up..................................................................415 F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up.................................................................416 F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up.............................................................417 F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up.............................................................418 F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up.................................................................419 F-6 Bit pattern 20-(6) Arm OUT oil pressure switch, does not light up...............................................................420 F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up............................................................421 F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up............................................................422 F-9 Bit pattern 21-(3) Swing lock switch does not light up..........................................................................423 F-11 Bit pattern 22-(6) L.H. knob switch does not light up..........................................................................424 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)....................................................................................425 PUMP MERGE/DIVIDER LOGIC................................................................................................................426 LS SELECT LOGIC.........................................................................................................................427 SOLENOID ACTUATION TABLE................................................................................................................427 TABLE OF FAILURE MODES AND CAUSES.......................................................................................................428 H-1 Speeds of all work equipment, swing, travel are slow or lack power..............................................................432 H-2 There is excessive drop in engine speed, or engine stalls.......................................................................434 H-3 No work equipment, travel, swing move...........................................................................................435 H-4 Abnormal noise generated (around pump)..........................................................................................435 H-5 Auto-deceleration does not work (when PPC shuttle valve is cause)...............................................................436 H-6 Fine control ability is poor or response is poor................................................................................437 H-7 Boom is slow or lacks power.....................................................................................................438 H-8 Arm is slow or lacks power......................................................................................................440 H-9 Bucket is slow or lacks power...................................................................................................442 H-10 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal).............................................443 H-11 Excessive hydraulic drift (boom, arm, bucket)..................................................................................443 H-12 Excessive time lag (engine at low idling)......................................................................................444 H-13 Other equipment moves when single circuit is relieved..........................................................................444 H-14 In L/O, F/O modes, work equipment speed is faster than specified speed.........................................................445 H-15 Defective actuation of machine push-up function................................................................................445 H-16 In compound operations, work equipment with larger load is slow................................................................445 H-17 In swing + boom RAISE, boom RAISE is slow......................................................................................446 H-18 In swing + arm, arm is slow....................................................................................................446 H-19 In swing + travel, travel speed drops excessively..............................................................................446 H-20 Travel deviation...............................................................................................................447 H-21 Travel speed is slow...........................................................................................................448 H-22 Steering does not turn easily or lacks power...................................................................................450 H-23 Travel speed does not switch or is faster than specified speed.................................................................452 H-24 Travel does not move (one side only)...........................................................................................452 H-25 Does not swing.................................................................................................................453 H-26 Swing acceleration is poor or swing speed is slow..............................................................................454 H-27 Excessive overrun when stopping swing..........................................................................................456 H-28 Excessive shock when stopping swing (one direction only).......................................................................457 H-29 Excessive abnormal noise when stopping swing...................................................................................457 H-30 Excessive hydraulic drift of swing.............................................................................................458 H-31 Swing speed is faster than specified swing speed...............................................................................459 TROUBLESHOOTING OF HYDRAULIC, MONITOR SYSTEM (M MODE).......................................................................................460 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................461 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE...................................................................................................463 M-1 [E101] Abnormality in error data is displayed...................................................................................466 M-2 [E103] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed...................467 M-3 [E104] Air cleaner clogging detected is displayed...............................................................................468 M-5 [E108] Engine water temperature 105°C detected is displayed.....................................................................468 M-6 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds .......................................469 M-7 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out....................................471 M-8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine(mode)....................471 M-9 When starting switch is turned ON (engine stopped), basic check items flashes...................................................472 M-11 When starting switch is turned ON and engine is started, basic check item flash................................................475 M-12 When starting switch is turned ON (engine speed), caution items, emergency items flash (battery, engine oil pressure lamp n....477 M-13 When starting switch is turned ON and engine is started, caution items, emergency items flash (when there is no abnormality....479 M-14 When staring switch is turned ON (engine stopped), buzzer does not sound for 1 second Caution item flashes but does not sou....482 M-15 No abnormality is displayed on monitor but buzzer sounds.......................................................................482 M-16 Night light on monitor panel does not light up (liquid crystal display is normal)..............................................483 M-17 Coolant temperature gauge does not rise........................................................................................484 M-18 Coolant temperature gauge does not give any display (none of gauge lamps light up during operation)............................484 M-19 Fuel level gauge always displays FULL..........................................................................................485 M-20 Fuel level gauge does not give display.........................................................................................485 M-21 Swing lock switch is turned ON (LOCK) but 4 swing lock monitor) does not light up..............................................486 M-22 Swing prolix switch is turned ON (prolix) but 8 (swing lock monitor) does not flash............................................486 M-23 Service meter does not advance while engine is running.........................................................................487 M-24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed............................487 M-25 Defective fuel level sensor system.............................................................................................488 M-26 Defective coolant temperature sensor system....................................................................................489 M-27 Defective engine oil level sensor system.......................................................................................490 M-28 Defective coolant level sensor system..........................................................................................491 M-29 Defective hydraulic oil level sensor system....................................................................................492 M-30 Wiper does not work or switch is not being used but wiper is actuated..........................................................493 30 DISASSEMBLY AND ASSEMBLY.........................................................................................................................497 METHOD OF USING MANUAL..........................................................................................................................499 PRECAUTIONS WHEN CARRYING OUT OPERATION.........................................................................................................501 SPECIAL TOOL LIST...............................................................................................................................503 SKETCHES OF SPECIAL TOOLS.......................................................................................................................509 STARTING MOTOR..................................................................................................................................517 ALTERNATOR......................................................................................................................................517 ENGINE OIL COOLER...............................................................................................................................517 FUEL INJECTION PUMP.............................................................................................................................517 WATER PUMP......................................................................................................................................518 NOZZLE HOLDER...................................................................................................................................518 TURBOCHARGER....................................................................................................................................518 THERMOSTAT......................................................................................................................................518 ENGINE FRONT SEAL...............................................................................................................................519 ENGINE REAR SEAL................................................................................................................................519 CYLINDER HEAD...................................................................................................................................519 AFTER COOLER....................................................................................................................................519 GOVERNOR MOTOR..................................................................................................................................520 REMOVAL.....................................................................................................................................520 INSTALLATION................................................................................................................................520 HYDRAULIC COOLER................................................................................................................................521 REMOVAL.....................................................................................................................................521 INSTALLATION................................................................................................................................522 RADIATOR, HYDRAULIC COOLER......................................................................................................................523 REMOVAL.....................................................................................................................................523 INSTALLATION................................................................................................................................524 ENGINE, MAIN PUMP...............................................................................................................................525 REMOVAL.....................................................................................................................................525 INSTALLATION................................................................................................................................528 DAMPER..........................................................................................................................................529 REMOVAL.....................................................................................................................................529 INSTALLATION................................................................................................................................529 FUEL TANK.......................................................................................................................................530 REMOVAL.....................................................................................................................................530 INSTALLATION................................................................................................................................530 CENTER SWIVEL JOINT.............................................................................................................................531 REMOVAL.....................................................................................................................................531 INSTALLATION................................................................................................................................531 DISASSEMBLY.................................................................................................................................532 ASSEMBLY....................................................................................................................................532 FINAL DRIVE.....................................................................................................................................533 REMOVAL.....................................................................................................................................533 INSTALLATION................................................................................................................................533 DISASSEMBLY.................................................................................................................................534 ASSEMBLY....................................................................................................................................538 TRAVEL MOTOR....................................................................................................................................545 DISASSEMBLY.................................................................................................................................545 ASSEMBLY....................................................................................................................................549 SPROCKET........................................................................................................................................560 REMOVAL.....................................................................................................................................560 INSTALLATION................................................................................................................................560 SWING MOTOR.....................................................................................................................................561 REMOVAL.....................................................................................................................................561 INSTALLATION................................................................................................................................561 DISASSEMBLY.................................................................................................................................562 ASSEMBLY....................................................................................................................................565 SWING MACHINERY.................................................................................................................................572 REMOVAL.....................................................................................................................................572 INSTALLATION................................................................................................................................572 DISASSEMBLY.................................................................................................................................573 ASSEMBLY....................................................................................................................................577 REVOLVING FRAME.................................................................................................................................582 REMOVAL.....................................................................................................................................582 INSTALLATION................................................................................................................................583 SWING CIRCLE....................................................................................................................................584 REMOVAL.....................................................................................................................................584 INSTALLATION................................................................................................................................584 IDLER, RECOIL SPRING............................................................................................................................585 REMOVAL.....................................................................................................................................585 INSTALLATION................................................................................................................................585 IDLER...........................................................................................................................................586 DISASSEMBLY.................................................................................................................................586 ASSEMBLY....................................................................................................................................587 RECOIL SPRING...................................................................................................................................589 DISASSEMBLY.................................................................................................................................589 ASSEMBLY....................................................................................................................................590 TRACK ROLLER....................................................................................................................................591 REMOVAL.....................................................................................................................................591 INSTALLATION................................................................................................................................591 DISASSEMBLY.................................................................................................................................592 ASSEMBLY....................................................................................................................................593 CARRIER ROLLER..................................................................................................................................595 REMOVAL.....................................................................................................................................595 INSTALLATION................................................................................................................................595 DISASSEMBLY.................................................................................................................................596 ASSEMBLY....................................................................................................................................597 TRACK SHOE......................................................................................................................................600 REMOVAL.....................................................................................................................................600 INSTALLATION................................................................................................................................600 HYDRAULIC TANK..................................................................................................................................601 REMOVAL.....................................................................................................................................601 INSTALLATION................................................................................................................................602 CONTROL PUMP....................................................................................................................................603 REMOVAL.....................................................................................................................................603 INSTALLATION................................................................................................................................603 MAIN PUMP.......................................................................................................................................604 REMOVAL.....................................................................................................................................604 INSTALLATION................................................................................................................................605 DISASSEMBLY.................................................................................................................................606 ASSEMBLY....................................................................................................................................612 CHECKING CONTACT............................................................................................................................622 MAIN PUMP INPUT SHAFT OIL SEAL..................................................................................................................624 REMOVAL.....................................................................................................................................624 INSTALLATION................................................................................................................................624 CONTROL VALVE...................................................................................................................................625 REMOVAL.....................................................................................................................................625 INSTALLATION................................................................................................................................627 DISASSEMBLY.................................................................................................................................628 ASSEMBLY....................................................................................................................................631 PUMP MERGE/DIVIDER VALVE........................................................................................................................635 DISASSEMBLY.................................................................................................................................635 ASSEMBLY....................................................................................................................................635 PRESSURE COMPENSATION VALVE.....................................................................................................................636 DISASSEMBLY.................................................................................................................................636 ASSEMBLY....................................................................................................................................636 SERVO VALVE FOR FRONT PUMP......................................................................................................................637 REMOVAL.....................................................................................................................................637 INSTALLATION................................................................................................................................637 SERVO VALVE FOR REAR PUMP.......................................................................................................................638 REMOVAL.....................................................................................................................................638 INSTALLATION................................................................................................................................638 LS-EPC SOLENOID VALVE...........................................................................................................................639 REMOVAL.....................................................................................................................................639 INSTALLATION................................................................................................................................639 SOLENOID VALVE..................................................................................................................................640 REMOVAL.....................................................................................................................................640 INSTALLATION................................................................................................................................640 WORK EQUIPMENT PPC VALVE........................................................................................................................641 REMOVAL.....................................................................................................................................641 INSTALLATION................................................................................................................................641 DISASSEMBLY.................................................................................................................................642 ASSEMBLY....................................................................................................................................642 TRAVEL PPC VALVE................................................................................................................................643 REMOVAL.....................................................................................................................................643 INSTALLATION................................................................................................................................643 DISASSEMBLY.................................................................................................................................644 ASSEMBLY....................................................................................................................................645 PPC SHUTTLE VALVE...............................................................................................................................646 REMOVAL.....................................................................................................................................646 INSTALLATION................................................................................................................................647 DISASSEMBLY.................................................................................................................................648 ASSEMBLY....................................................................................................................................649 BOOM LOCK VALVE.................................................................................................................................650 REMOVAL.....................................................................................................................................650 INSTALLATION................................................................................................................................650 DISASSEMBLY.................................................................................................................................650 ASSEMBLY....................................................................................................................................650 BOOM CYLINDER...................................................................................................................................651 REMOVAL.....................................................................................................................................651 INSTALLATION................................................................................................................................652 ARM CYLINDER....................................................................................................................................653 REMOVAL.....................................................................................................................................653 INSTALLATION................................................................................................................................654 BUCKET CYLINDER.................................................................................................................................655 REMOVAL.....................................................................................................................................655 INSTALLATION................................................................................................................................656 HYDRAULIC CYLINDER..............................................................................................................................657 DISASSEMBLY.................................................................................................................................657 ASSEMBLY....................................................................................................................................659 WORK EQUIPMENT..................................................................................................................................661 REMOVAL.....................................................................................................................................661 INSTALLATION................................................................................................................................662 BUCKET..........................................................................................................................................663 REMOVAL.....................................................................................................................................663 INSTALLATION................................................................................................................................664 ARM.............................................................................................................................................665 REMOVAL.....................................................................................................................................665 INSTALLATION................................................................................................................................666 BUCKET, ARM.....................................................................................................................................667 REMOVAL.....................................................................................................................................667 INSTALLATION................................................................................................................................668 BOOM............................................................................................................................................669 REMOVAL.....................................................................................................................................669 INSTALLATION................................................................................................................................670 OPERATORS CAB...................................................................................................................................671 REMOVAL.....................................................................................................................................671 INSTALLATION................................................................................................................................672 COUNTERWEIGHT...................................................................................................................................673 REMOVAL.....................................................................................................................................673 INSTALLATION ...............................................................................................................................673 COUNTERWEIGHT WITH COUNTERWEIGHT REMOVER........................................................................................................674 REMOVAL.....................................................................................................................................674 INSTALLATION................................................................................................................................677 AIR CONDITIONER COMPRESSOR......................................................................................................................678 REMOVAL.....................................................................................................................................678 INSTALLATION................................................................................................................................678 CONDENSER.......................................................................................................................................679 REMOVAL.....................................................................................................................................679 INSTALLATION................................................................................................................................679 AIR CONDITIONER.................................................................................................................................680 REMOVAL.....................................................................................................................................680 INSTALLATION................................................................................................................................681 GOVERNOR, PUMP CONTROLLER.......................................................................................................................682 REMOVAL.....................................................................................................................................682 INSTALLATION................................................................................................................................682 MONITOR PANEL...................................................................................................................................683 REMOVAL.....................................................................................................................................683 INSTALLATION................................................................................................................................683 CONTROL STAND CASE..............................................................................................................................684 REMOVAL.....................................................................................................................................684 INSTALLATION................................................................................................................................685 40 MAINTENANCE STANDARD.............................................................................................................................686 ENGINE MOUNT....................................................................................................................................687 RADIATOR AND OIL COOLER.........................................................................................................................688 SWING MACHINERY.................................................................................................................................689 FINAL DRIVE.....................................................................................................................................691 SWING CIRCLE....................................................................................................................................693 TRACK FRAME AND RECOIL SPRING - PC400LC-6.......................................................................................................694 TRACK FRAME AND RECOIL SPRING - PC400HD-6.......................................................................................................695 CARRIER ROLLER..................................................................................................................................697 IDLER...........................................................................................................................................698 TRACK...........................................................................................................................................700 TRACK ROLLER....................................................................................................................................702 HYDRAULIC PUMP..................................................................................................................................703 CONTROL PUMP AND RELIEF VALVE...................................................................................................................704 CONTROL VALVE...................................................................................................................................705 SUCTION SAFETY VALVE............................................................................................................................711 SWING MOTOR.....................................................................................................................................712 TRAVEL MOTOR....................................................................................................................................713 WORK EQUIPMENT, SWING PPC VALVE.................................................................................................................714 TRAVEL PPC VALVE................................................................................................................................715 SERVICE PPC VALVE...............................................................................................................................716 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE........................................................................................................717 EPC SOLENOID VALVE..............................................................................................................................718 CENTER SWIVEL JOINT.............................................................................................................................719 BOOM HOLDING VALVE..............................................................................................................................720 HYDRAULIC CYLINDER..............................................................................................................................721 WORK EQUIPMENT..................................................................................................................................723 DIMENSIONS OF WORK EQUIPMENT....................................................................................................................725
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
