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Komatsu PC450-6K, PC450LC-6K K32001 and up, K34001 and up Hydraulic Excavator Shop Manual – DOWNLOAD
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Komatsu PC450-6K, PC450LC-6K K32001 and up, K34001 and up Hydraulic Excavator Shop Manual
Book Code: UEBM001301
MACHINE MODEL SERIAL NUMBER
PC450-6K K32001 and up
K34001 and up
PC450LC-6K K32001 and up
K34001 and up
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Description
Komatsu PC450-6K, PC450LC-6K K32001 and up, K34001 and up Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC450-6K, PC450LC-6K K32001 and up, K34001 and up Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC450-6K, PC450LC-6K
Serial Number: K32001 and up, K34001 and up
Book Code: UEBM001301
Language: English
Pages: 839
File Format: Portable Document Format (PDF)
KOMATSU PC450-6K, PC450LC-6K K32001 AND UP, K34001 AND UP HYDRAULIC EXCAVATOR SHOP MANUAL – DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC450-6K, PC450LC-6K K32001 and up, K34001 and up Hydraulic Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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.
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 thissection.
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 PC450-6K, PC450LC-6K K32001 and up, K34001 and up Hydraulic Excavator Shop Manual
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 SAFETY....................................................................................................................................... 7 SAFETY NOTICE............................................................................................................................ 7 FOREWARD..................................................................................................................................... 9 GENERAL.................................................................................................................................. 9 HOW TO READ THE SHOP MANUAL.............................................................................................................. 10 HOISTING INSTRUCTIONS.................................................................................................................... 11 COATING MATERIALS........................................................................................................................ 12 STANDARD TIGHTENING TORQUE............................................................................................................... 14 ELECTRIC WIRE CODE....................................................................................................................... 17 CONVERSION TABLE......................................................................................................................... 18 01 GENERAL................................................................................................................................... 26 SPECIFICATION DRAWINGS................................................................................................................... 27 SPECIFICATIONS........................................................................................................................... 28 WEIGHT TABLE (SERIAL NO'S 32001 and up).................................................................................................. 31 WEIGHT TABLE (SERIAL NO'S 34001 and up).................................................................................................. 35 FUEL, COOLANT AND LUBRICANTS............................................................................................................. 37 10 STRCTURE AND FUNCTION..................................................................................................................... 41 PARTS RELATED TO ENGINE.................................................................................................................. 42 RADIATOR, OIL COOLER..................................................................................................................... 44 POWER TRAIN.............................................................................................................................. 45 FINAL DRIVE.............................................................................................................................. 46 SWING CIRCLE............................................................................................................................. 47 SWING MACHINERY.......................................................................................................................... 48 TRACK FRAME, RECOIL SPRING............................................................................................................... 49 TRACK SHOE............................................................................................................................... 50 HYDRAULIC PIPING DRAWING................................................................................................................. 52 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 54 HYDRAULIC TANK, HYDRAULIC FILTER K32001 - K33999......................................................................................... 55 HYDRAULIC TANK, HYDRAULIC FILTER K34001 AND UP....................................................................................... 56 HYDRAULIC PUMP........................................................................................................................... 57 CONTROL VALVE............................................................................................................................ 78 SELF-REDUCING PRESSURE VALVE............................................................................................................. 88 SUCTION SAFETY VALVE..................................................................................................................... 93 CLSS..................................................................................................................................... 95 SWING MOTOR..............................................................................................................................160 CENTER SWIVEL JOINT......................................................................................................................166 TRAVEL MOTOR.............................................................................................................................168 VALVE CONTROL............................................................................................................................177 WORK EQUIPMENT * SWING PPC VALVE.........................................................................................................178 TRAVEL PPC VALVE.........................................................................................................................182 SERVICE PPC VALVE........................................................................................................................186 PPC SAFETY LOCK VALVE....................................................................................................................189 PPC ACCUMULATOR..........................................................................................................................189 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE.................................................................................................191 LS-EPC VALVE.............................................................................................................................198 SOLENOID VALVE...........................................................................................................................202 BOOM SAFETY VALVE........................................................................................................................204 OVERLOAD WARNING DEVICE..................................................................................................................207 WORK EQUIPMENT...........................................................................................................................209 AIR CONDITIONER..........................................................................................................................210 ACTUAL ELECTRIC WIRING DIAGRAM...........................................................................................................211 ELECTRIC CIRCUIT DIAGRAM.................................................................................................................215 ENGINE CONTROL...........................................................................................................................218 ELECTRONIC CONTROL SYSTEM................................................................................................................225 MACHINE MONITOR SYSTEM...................................................................................................................252 BREAKER MODE HYDRAULIC PERFORMANCE.......................................................................................................263 20 TESTING AND ADJUSTING.....................................................................................................................266 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS............................................................................................267 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...........................................................................................268 STANDARD VALUE TABLE FOR ELECTRICAL PARTS................................................................................................276 TESTING AND ADJUSTING....................................................................................................................284 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....................................................................................285 MEASURING ENGINE SPEED...............................................................................................................286 MEASURING EXHAUST COLOR..............................................................................................................287 ADJUSTING VALVE CLEARANCE............................................................................................................288 MEASURING COMPRESSION PRESSURE.......................................................................................................289 MEASURING BLOW-BY PRESSURE...........................................................................................................289 TESTING AND ADJUSTING FUEL INJECTION TIMING..........................................................................................290 MEASURING ENGINE OIL PRESSURE........................................................................................................292 TESTING AND ADJUSTING FAN BELT TENSION...............................................................................................293 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR....................................................................293 ADJUSTING ENGINE SPEED SENSOR........................................................................................................294 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).......................................................................................295 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE....................................................................................296 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....................................................297 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)........................................................300 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE............................302 TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF PRESSURE IS REDUCED)....................................................305 TESTING SOLENOID VALVE OUTPUT PRESSURE...............................................................................................306 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE....................................................................309 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE............................................................................................311 TESTING TRAVEL DEVIATION.............................................................................................................312 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT..........................................................................313 MEASURING OIL LEAKAGE................................................................................................................315 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....................................................................................317 TESTING CLEARANCE OF SWING CIRCLE BEARING............................................................................................318 TESTING WEAR OF SPROCKET.............................................................................................................319 TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................................320 BLEEDING AIR.........................................................................................................................321 TROUBLESHOOTING..........................................................................................................................324 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................325 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................326 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....................................................................................327 CHECKS BEFORE TROUBLESHOOTING........................................................................................................335 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................337 CONNECTOR ARRANGEMENT DIAGRAM........................................................................................................339 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................342 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...............................................................................352 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL................................................................................353 METHOD OF USING JUDGEMENT TABLE......................................................................................................362 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................364 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE.............................................................................366 SERVICE CODE TABLE...................................................................................................................371 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE).........................................................................372 N-1 [E218] COMMUNICATION ABNORMALITY.............................................................................................373 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)......................................................376 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM.........................................377 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.......................................................379 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS.................................383 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM.....................................................................................385 E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)................................................387 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED.............................................................388 E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................389 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................390 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED.............................................................391 E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED...............................................392 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED..........................................................................393 E-8 ENGINE DOES NOT START........................................................................................................395 E-9 ENGINE SPEED IS IRREGULAR....................................................................................................397 a) IDLING SPEED IN IRREGULAR.................................................................................................397 b) THERE IS HUNTING..........................................................................................................399 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)........................................................................401 E-11 ENGINE DOES NOT STOP........................................................................................................403 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)..........................................................405 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................408 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................409 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....................................................................413 S-2 ENGINE DOES NOT START........................................................................................................414 (1) ENGINE DOES NOT TURN.....................................................................................................414 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).................................................415 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...............................................416 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR).........................................................................417 S-4 ENGINE STOPS DURING OPERATIONS...............................................................................................418 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................419 S-6 ENGINE LACKS OUTPUT (NO POWER)...............................................................................................420 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...............................................................................421 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)......................................................................422 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................423 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................424 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.....................................................425 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..................................................................426 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)........................................................................................427 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................428 S-15 ABNORMAL NOISE IS MADE......................................................................................................429 S-16 VIBRATION IS EXCESSIVE......................................................................................................430 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)..........................................................432 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...................................................................433 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.......................................................435 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS..................................443 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE............................................................................................445 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)........................................................447 C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED..........................................................448 C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED..........................................................450 C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED...........................................................452 C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED...........................................................454 C-6 [E207] SHORT CIRCUIT IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED......................................................456 C-7 [E208] DISCONNECTION IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED......................................................457 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................458 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................460 C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER DOLENOID SYSTEM IS DISPLAYED.....................................................462 C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED.....................................................463 C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...........................................................464 C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED..................................................465 C-14 [E231] SHORT CIRCUIT IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED....................................................466 C-15 [E235] DISCONNECTION IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED....................................................467 C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED.............................................................................468 C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.................................................................470 C-18 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.................................................................471 C-19 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED........................................................472 C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.........................................................473 C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED......................................................474 C-22 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...............................................................475 C-23 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)..................................................476 C-24 [E234] DISCONNECTION IN OVERLOAD WARNING SYSTEM.............................................................................478 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)..........................................................480 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE............................................................................................481 F-1 BIT PATTERN 20-(1) (SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP.............................................................483 F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP............................................................484 F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP........................................................485 F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP........................................................486 F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP............................................................487 F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP...........................................................488 F-7 BIT PATTERN 20-(7) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP.......................................................489 F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP.......................................................490 F-9 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP.....................................................................491 F-11 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP.....................................................................493 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)..............................................................................494 PUMP MERGE/DIVIDER LOGIC.........................................................................................................496 SOLENOID ACTUATION TABLE.....................................................................................................496 TABLE OF FAILURE MODES AND CAUSES (1/2)..........................................................................................497 TABLE OF FAILURE MODES AND CAUSES (2/2)......................................................................................499 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...........................................................501 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS....................................................................503 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE........................................................................................504 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP).......................................................................................504 H-5 AUTO-DECLARATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE).............................................................505 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR.............................................................................505 H-7 BOOM IS SLOW OR LACKS POWER..................................................................................................507 H-8 ARM IS SLOW OR LACKS POWER...................................................................................................509 H-9 BUCKET IS SLOW OR LACKS POWER................................................................................................511 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)..........................................512 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...............................................................................512 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...................................................................................513 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED.......................................................................513 H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED......................................................514 H-15 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION.............................................................................514 H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW.............................................................514 H-17 IN SWING + BOOM RAISE IS SLOW...............................................................................................515 H-18 IN SWING + ARM, ARM IS SLOW.................................................................................................515 H-19 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY...........................................................................515 H-20 TRAVEL DEVIATION............................................................................................................516 a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL..................................................................................516 b) EXCESSIVE TRAVEL DEVIATION WHEN STARTING..................................................................................516 H-21 TRAVEL SPEED IS SLOW........................................................................................................517 H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER................................................................................519 H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED..............................................................521 H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)........................................................................................521 H-25 DOES NOT SWING..............................................................................................................522 a) DOES NOT SWING TO EITHER LEFT OR RIGHT....................................................................................522 b) DOES NOT SWING IN ONE DIRECTION...........................................................................................522 H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY).................................523 a) SWING ACCELERATION IS POOR................................................................................................523 H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING.......................................................................................525 a) ONE DIRECTION ONLY........................................................................................................525 b) BOTH DIRECTIONS...........................................................................................................525 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)....................................................................526 H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING................................................................................526 H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING..........................................................................................527 a) WHEN SWING HOLDING BRAKE IS RELEASED......................................................................................527 b) WHEN SWING HOLDING BRAKE IS APPLIED.......................................................................................527 H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED............................................................................528 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...................................................................................530 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................533 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM.....................................................................................535 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED [E102] ERROR IN CLOCK DATA IS DISPLAYED........................................537 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED................538 M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED............................................................................539 M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED..................................................................539 M-5 [E108] ENGINE WATER TEMPERATURE 105 C DETECTED IS DISPLAYED..................................................................540 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS.....................................541 a) NONE OF LAMPS ON MONITOR PANEL LIGHT UP...................................................................................541 b) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP............................................................................541 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT.................................543 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)...............543 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH..................................................544 a) (COOLANT LEVEL) FLASHES...................................................................................................544 b) (ENGINE OIL LEVEL) FLASHES................................................................................................545 c) (HYDRAULIC OIL LEVEL) FLASHES.............................................................................................546 M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP.............................................................547 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH............................................548 a) ALTERNATOR SYSTEM.........................................................................................................548 b) ENGINE OIL PRESSURE SYSTEM................................................................................................549 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE L....550 a) ALTERNATOR SYSTEM.........................................................................................................550 b) ENGINE OIL PRESSURE SENSOR SYSTEM.........................................................................................551 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMAL....552 a) (ENGINE OIL PRESSURE) FLASHES.............................................................................................552 b) (COOLANT LEVEL) FLASHES...................................................................................................552 b) (BATTERY CHARGE) FLASHES..................................................................................................552 d) (COOLANT TEMPERATURE) FLASHES.............................................................................................553 e) (FUEL LEVEL) FLASHES......................................................................................................553 f) (AIR CLEANER CLOGGING) FLASHES............................................................................................554 M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER D....555 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS....................................................................555 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)........................................556 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE.....................................................................................557 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION).........................557 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL.......................................................................................558 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY......................................................................................558 M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP............................................559 M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH..........................................559 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING......................................................................560 M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED.........................560 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM..........................................................................................561 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM.................................................................................562 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM....................................................................................563 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.......................................................................................564 M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM.................................................................................565 M-30 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113).................................567 a) WIPER DOES NOT WORK.......................................................................................................567 b) WIPER SWITCH IS NOT BEING OPERATED BUT WIPER IS ACTUATED..................................................................571 M-31 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114).........................572 a) WASHER MOTOR DOES NOT WORK................................................................................................572 b) SWITCH IS NOT BEING OPERATED BUT WASHER IS ACTUATED.......................................................................573 M-32 ELECTRIC GREASE GUN DOES NOT WORK...........................................................................................574 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................577 METHOD OF USING MANUAL...................................................................................................................579 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................581 SPECIAL TOOL LIST........................................................................................................................583 SKETCHES OF SPECIAL TOOLS................................................................................................................589 STARTING MOTOR ASSEMBLY..................................................................................................................594 REMOVAL AND INSTALLATION.............................................................................................................594 ALTERNATOR ASSEMBLY......................................................................................................................595 REMOVAL AND INSTALLATION.............................................................................................................595 ENGINE OIL COOLER ASSEMBLY...............................................................................................................596 REMOVAL AND INSTALLATION.............................................................................................................596 FUEL INJECTION PUMP ASSEMBLY.............................................................................................................597 REMOVAL..............................................................................................................................597 INSTALLATION.........................................................................................................................599 WATER PUMP ASSEMBLY......................................................................................................................600 REMOVAL AND INSTALLATION.............................................................................................................600 NOZZLE HOLDER ASSEMBLY...................................................................................................................601 REMOVAL AND INSTALLATION.............................................................................................................601 TURBOCHARGER ASSEMBLY....................................................................................................................602 REMOVAL AND INSTALLATION.............................................................................................................602 THERMOSTAT ASSEMBLY......................................................................................................................603 REMOVAL AND INSTALLATION.............................................................................................................603 ENGINE FRONT SEAL........................................................................................................................604 REMOVAL AND INSTALLATION.............................................................................................................604 ENGINE REAR SEAL.........................................................................................................................605 REMOVAL..............................................................................................................................605 INSTALLATION.........................................................................................................................606 CYLINDER HEAD ASSEMBLY...................................................................................................................609 REMOVAL..............................................................................................................................609 INSTALLATION.........................................................................................................................613 GOVERNOR MOTOR ASSEMBLY..................................................................................................................616 REMOVAL AND INSTALLATION.............................................................................................................616 AFTERCOOLER ASSEMBLY.....................................................................................................................617 REMOVAL AND INSTALLATION.............................................................................................................617 AFTERCOOLER CORE ASSEMBLY................................................................................................................619 REMOVAL AND INSTALLATION.............................................................................................................619 HYDRAULIC COOLER ASSEMBLY................................................................................................................620 REMOVAL..............................................................................................................................620 INSTALLATION.........................................................................................................................621 RADIATOR, HYDRAULIC COOLER ASSEMBLY......................................................................................................622 REMOVAL..............................................................................................................................622 INSTALLATION.........................................................................................................................624 ENGINE, MAIN PUMP ASSEMBLY...............................................................................................................625 REMOVAL..............................................................................................................................625 INSTALLATION.........................................................................................................................628 DAMPER ASSEMBLY..........................................................................................................................629 REMOVAL AND INSTALLATION.............................................................................................................629 FUEL TANK ASSEMBLY.......................................................................................................................630 REMOVAL AND INSTALLATION.............................................................................................................630 CENTER SWIVEL JOINT ASSEMBLY.............................................................................................................631 REMOVAL AND INSTALLATION.............................................................................................................631 DISASSEMBLY AND ASSEMBLY.............................................................................................................632 FINAL DRIVE ASSEMBLY.....................................................................................................................633 REMOVAL AND INSTALLATION.............................................................................................................633 DISASSEMBLY..........................................................................................................................634 ASSEMBLY.............................................................................................................................638 TRAVEL MOTOR ASSEMBLY....................................................................................................................644 DISASSEMBLY..........................................................................................................................644 ASSEMBLY.............................................................................................................................649 SPROCKET.................................................................................................................................660 REMOVAL AND INSTALLATION.............................................................................................................660 SWING MOTOR ASSEMBLY.....................................................................................................................661 REMOVAL AND INSTALLATION.............................................................................................................661 SWING MACHINERY ASSEMBLY.................................................................................................................662 REMOVAL AND INSTALLATION.............................................................................................................662 DISASSEMBLY..........................................................................................................................663 ASSEMBLY.............................................................................................................................667 REVOLVING FRAME ASSEMBLY.................................................................................................................672 REMOVAL..............................................................................................................................672 INSTALLATION.........................................................................................................................673 SWING CIRCLE ASSEMBLY....................................................................................................................674 REMOVAL AND INSTALLATION.............................................................................................................674 IDLER, RECOIL SPRING ASSEMBLY............................................................................................................675 REMOVAL AND INSTALLATION.............................................................................................................675 IDLER ASSEMBLY...........................................................................................................................676 DISASSEMBLY..........................................................................................................................676 ASSEMBLY.............................................................................................................................677 RECOIL SPRING ASSEMBLY...................................................................................................................679 DISASSEMBLY..........................................................................................................................679 ASSEMBLY.............................................................................................................................680 TRACK ROLLER ASSEMBLY....................................................................................................................681 REMOVAL AND INSTALLATION.............................................................................................................681 DISASSEMBLY..........................................................................................................................682 ASSEMBLY.............................................................................................................................683 CARRIER ROLLER ASSEMBLY..................................................................................................................685 REMOVAL AND INSTALLATION.............................................................................................................685 DISASSEMBLY..........................................................................................................................686 ASSEMBLY.............................................................................................................................688 TRACK SHOE ASSEMBLY......................................................................................................................690 REMOVAL AND INSTALLATION.............................................................................................................690 HYDRAULIC TANK ASSEMBLY..................................................................................................................691 REMOVAL..............................................................................................................................691 INSTALLATION.........................................................................................................................692 MAIN PUMP ASSEMBLY.......................................................................................................................693 REMOVAL..............................................................................................................................693 INSTALLATION.........................................................................................................................694 DISASSEMBLY..........................................................................................................................695 ASSEMBLY.............................................................................................................................701 MAIN PUMP INPUT SHAFT OIL SEAL...........................................................................................................717 REMOVAL AND INSTALLATION.............................................................................................................717 CONTROL VALVE ASSEMBLY...................................................................................................................718 REMOVAL..............................................................................................................................718 INSTALLATION.........................................................................................................................720 DISASSEMBLY..........................................................................................................................721 ASSEMBLY.............................................................................................................................727 PUMP MERGE/DIVIDER VALVE ASSEMBLY........................................................................................................734 DISASSEMBLY AND ASSEMBLY.............................................................................................................734 PRESSURE COMPENSATION VALVE ASSEMBLY.....................................................................................................735 DISASSEMBLY AND ASSEMBLY.............................................................................................................735 SERVO VALVE ASSEMBLY FOR FRONT PUMP......................................................................................................736 REMOVAL AND INSTALLATION.............................................................................................................736 SERVO VALVE ASSEMBLY FOR REAR PUMP.......................................................................................................737 REMOVAL AND INSTALLATION.............................................................................................................737 LS-EPC SOLENOID VALVE ASSEMBLY...........................................................................................................738 REMOVAL AND INSTALLATION.............................................................................................................738 SOLENOID VALVE ASSEMBLY..................................................................................................................739 REMOVAL AND INSTALLATION.............................................................................................................739 WORK EQUIPMENT PPC VALVE ASSEMBLY........................................................................................................740 REMOVAL AND INSTALLATION.............................................................................................................740 DISASSEMBLY..........................................................................................................................741 ASSEMBLY.............................................................................................................................742 TRAVEL PPC VALVE ASSEMBLY................................................................................................................743 REMOVAL AND INSTALLATION.............................................................................................................743 DISASSEMBLY..........................................................................................................................744 ASSEMBLY.............................................................................................................................745 PPC SHUTTLE VALVE ASSEMBLY...............................................................................................................746 REMOVAL..............................................................................................................................746 INSTALLATION.........................................................................................................................747 DISASSEMBLY..........................................................................................................................748 ASSEMBLY.............................................................................................................................749 BOOM CYLINDER ASSEMBLY...................................................................................................................750 REMOVAL..............................................................................................................................750 INSTALLATION.........................................................................................................................751 ARM CYLINDER ASSEMBLY....................................................................................................................752 REMOVAL..............................................................................................................................752 INSTALLATION.........................................................................................................................753 BUCKET CYLINDER ASSEMBLY.................................................................................................................754 REMOVAL..............................................................................................................................754 INSTALLATION.........................................................................................................................755 HYDRAULIC CYLINDER ASSEMBLY..............................................................................................................756 DISASSEMBLY..........................................................................................................................756 ASSEMBLY.............................................................................................................................759 WORK EQUIPMENT ASSEMBLY..................................................................................................................763 REMOVAL..............................................................................................................................763 INSTALLATION.........................................................................................................................764 BUCKET ASSEMBLY..........................................................................................................................765 REMOVAL..............................................................................................................................765 INSTALLATION.........................................................................................................................766 ARM ASSEMBLY.............................................................................................................................767 REMOVAL..............................................................................................................................767 INSTALLATION.........................................................................................................................768 BUCKET, ARM ASSEMBLY.....................................................................................................................769 REMOVAL..............................................................................................................................769 INSTALLATION.........................................................................................................................770 BOOM ASSEMBLY............................................................................................................................771 REMOVAL..............................................................................................................................771 INSTALLATION.........................................................................................................................772 OPERATOR'S CAB ASSEMBLY..................................................................................................................773 REMOVAL..............................................................................................................................773 INSTALLATION.........................................................................................................................774 COUNTERWEIGHT ASSEMBLY...................................................................................................................775 REMOVAL AND INSTALLATION.............................................................................................................775 AIR CONDITIONER COMPRESSOR ASSEMBLY......................................................................................................776 REMOVAL AND INSTALLATION.............................................................................................................776 CONDENSER ASSEMBLY.......................................................................................................................777 REMOVAL AND INSTALLATION.............................................................................................................777 RECEIVER TANK ASSEMBLY...................................................................................................................778 REMOVAL AND INSTALLATION.............................................................................................................778 AIR CONDITIONER UNIT ASSEMBLY............................................................................................................779 REMOVAL..............................................................................................................................779 INSTALLATION.........................................................................................................................780 GOVERNOR, PUMP CONTROLLER ASSEMBLY.......................................................................................................781 REMOVAL AND INSTALLATION.............................................................................................................781 MONITOR PANEL ASSEMBLY...................................................................................................................782 REMOVAL AND INSTALLATION.............................................................................................................782 CONTROL STAND CASE.......................................................................................................................783 REMOVAL..............................................................................................................................783 INSTALLATION.........................................................................................................................784 40 MAINTENANCE STANDARD......................................................................................................................786 ENGINE MOUNT.............................................................................................................................787 SWING MACHINERY..........................................................................................................................789 SWING CIRCLE.............................................................................................................................791 FINAL DRIVE..............................................................................................................................792 TRACK FRAME AND RECOIL SPRING............................................................................................................794 IDLER....................................................................................................................................796 CARRIER ROLLER...........................................................................................................................798 TRACK ROLLER.............................................................................................................................799 TRACK SHOE (TRIPLE GROUSER SHOE).........................................................................................................800 HYDRAULIC PUMP...........................................................................................................................804 CONTROL VALVE............................................................................................................................806 SELF-REDUCING PRESSURE VALVE.............................................................................................................813 SUCTION SAFETY VALVE.....................................................................................................................814 SWING MOTOR..............................................................................................................................815 TRAVEL MOTOR.............................................................................................................................816 WORK EQUIPMENT, SWING PPC VALVE..........................................................................................................817 TRAVEL PPC VALVE.........................................................................................................................818 SERVICE PPC VALVE........................................................................................................................819 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE.................................................................................................820 LS-EPC VALVE.............................................................................................................................821 SOLENOID VALVE...........................................................................................................................822 CENTER SWIVEL JOINT......................................................................................................................824 HYDRAULIC CYLINDER.......................................................................................................................826 WORK EQUIPMENT...........................................................................................................................828 DIMENSIONS OF WORK EQUIPMENT.............................................................................................................830 90 OTHERS....................................................................................................................................835 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................836 ELECTRIC CIRCUIT DIAGRAM (1/3)...........................................................................................................837 ELECTRIC CIRCUIT DIAGRAM (2/3)...........................................................................................................838 ELECTRIC CIRCUIT DIAGRAM (3/3)...........................................................................................................839
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1 review for Komatsu PC450-6K, PC450LC-6K K32001 and up, K34001 and up Hydraulic Excavator Shop Manual – DOWNLOAD
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Alan Dennis –
Good product highly recommended seller