Komatsu PC400LC-6 PC400HD-6 Hydraulic Excavator Shop Manual CEBM4006C3 PDF

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Komatsu PC400LC-6 PC400HD-6 Hydraulic Excavator Shop Manual CEBM4006C3  – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC400LC-6 PC400HD-6 Hydraulic Excavator Shop Manual CEBM4006C3  – PDF DOWNLOAD

Language : English
Pages : 836
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC400LC-6 PC400HD-6 Hydraulic Excavator Shop Manual CEBM4006C3  – PDF DOWNLOAD

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

DESCRIPTION:

Komatsu PC400LC-6 PC400HD-6 Hydraulic Excavator Shop Manual CEBM4006C3  – PDF DOWNLOAD

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 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, ADJUSTING AND TROUBLESHOOTING
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.
NOTICE

G.B  14/12/24