Komatsu PC450-7K PC450LC-7K Shop Manual – PDF DOWNLOAD

Description

Komatsu PC450-7K PC450LC-7K Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC450-7K PC450LC-7K Shop Manual – PDF DOWNLOAD

Language : English
Pages : 766
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC450-7K PC450LC-7K Shop Manual – PDF DOWNLOAD

SERIAL NUMBER
K40001 AND UP
K40001 AND UP

COVER 1
CONTENTS 2
Forewordpdf 0
SAFETY 3
SAFETY NOTICE 3
FOREWORD 5
GENERAL 5
HOW TO READ THE SHOP MANUAL 6
HOISTING INSTRUCTIONS 7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 8
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 15
CONVERSION TABLE 16
UNITS 22
01pdf 0
01 GENERAL 23
SPECIFICATION DRAWINGS 24
SPECIFICATIONS 26
WEIGHT TABLE 28
FUEL, COOLANT AND LUBRICANTS 30
10SERVERpdf 0
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 31
ENGINE RELATED PARTS 32
RADIATOR•OIL COOLER•AFTERCOOLER 33
POWER TRAIN 34
FINAL DRIVE 36
SWING MACHINERY 38
SWING CIRCLE 40
TRACK FRAME AND RECOIL SPRING 42
IDLER 44
CARRIER ROLLER 46
TRACK ROLLER 47
TRACK SHOE 48
HYDRAULIC PIPING DRAWING 52
HYDRAULIC TANK 54
HYDRAULIC PUMP 56
LS(pc)-EPC VALVE 74
variable volume valve 77
CONTROL VALVE 80
MAIN RELIEF VALVE 94
CLSS 96
SELF PRESSURE REDUCING VALVE 99
SWING MOTOR102
CENTER SWIVEL JOINT110
TRAVEL MOTOR112
TRAVEL JUNCTION VALVE123
VALVE CONTROL125
TRAVEL PPC SHUTTLE VALVE126
WORK EQUIPMENT • SWING PPC VALVE130
TRAVEL PPC VALVE134
SERVICE PPC VALVE141
SOLENOID VALVE142
PPC ACCUMULATOR144
return oil filter145
quick return valve146
LIFT CHECK VALVE148
attachment circuit selector valve149
HOLDING VALVE151
HYDRAULIC CYLINDER156
WORK EQUIPMENT158
AIR CONDITIONER164
ENGINE CONTROL165
ELECTRONIC CONTROL SYSTEM171
MONITOR SYSTEM198
SENSOR218
20_001pdf 0
20 TESTING AND ADJUSTING221
STANDARD VALUE TABLE FOR ENGINE222
STANDARD VALUE TABLE FOR CHASSIS223
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TESTING AND ADJUSTING233
Testing, adjusting, and troubleshooting tools table234
Measuring engine speed236
Measuring intake air pressure (boost pressure)237
Measuring exhaust temperature238
Measuring exhaust gas color239
Adjusting valve clearance240
Measuring compression pressure242
Measuring blow-by pressure244
Measuring engine oil pressure245
Handling of fuel system devices246
Releasing residual pressure from fuel system246
Measuring fuel pressure247
Bleeding air from fuel circuit248
Inspection of fuel circuit for leakage250
Adjusting engine speed sensor251
Testing and adjusting fan belt and alternator belt tension252
Testing and adjusting air conditioner compressor belt tension253
Measuring clearance of swing circle bearing254
Testing and adjusting track shoe tension255
Testing and adjusting oil pressure in work equipment, swing, and travel circuits256
Measuring basic pressure in control circuit260
Testing and adjusting oil pressure in pump PC control circuit261
Testing and adjusting oil pressure in pump LS control circuit264
Measuring solenoid valve output pressure269
Measuring PPC valve output pressure272
Adjusting play of work equipment and swing PPC valves274
Testing parts which cause hydraulic drift of work equipment275
Releasing residual pressure in hydraulic circuit277
Measuring oil leakage200
Bleeding air from each part281
Testing procedure of diode284
Special functions of monitor panel200
Ordinary functions and special functions of monitor panel286
Operation and display of Operator’s Menu (Outline)287
Table for Error and Failure Code Nos292
Operation and display of Service Menu295
Monitoring items list202
Handling of high-voltage circuit of engine controller312
Preparation work for troubleshooting for electrical equipment system203
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Pm-CLINIC SERVICE315
Pm-CLINIC SERVICE PC450 (LC)-7320
UNDERCARRIAGE INSPECTION321
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TROUBLESHOOTING233
POINTS TO REMEMBER WHEN TROUBLESHOOTING324
SEQUENCE OF EVENTS IN TROUBLESHOOTING320
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE326
CHECKS BEFORE TROUBLESHOOTING334
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING335
Classification of troubleshooting335
Steps for troubleshooting335
Phenomena considered to be failures and troubleshooting Nos336
Connector arrangement drawing and electric circuit diagram of each system339
Connectors list339
Connector Location Stereogram344
Monitor Panel System Circuit Diagram (M Circuit)350
Engine Control System Circuit Diagram (E Ciruit)352
Pump Controller System Circuit Diagram (P Circuit)354
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS356
T-BRANCH BOX AND T-BRANCH TABLE378
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TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISP381
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE384
Error Code in Electrical System [E112] (Short-circuiting in normal rotation system of windshield 386
Error Code in Electrical System [E113] (Short-circuiting in reverse rotation system of windshield388
Error Code in Electrical System [E114] (Short-circuiting in window washer drive system)390
Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion)392
Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper)394
Error Code in Electrical System [E117] (Eng Controller S-NET Comm Err)396
Error Code in Electrical System [E118] (Pump Controller S-NET Comm Err)398
Error Code in Electrical System [E128] (Monitor Comm Abnormality)400
Error Code in Electrical System [E201] (Short-circuiting in travel interlocking solenoid)402
Error Code in Electrical System [E203] (Short-circuiting in swing holding brake solenoid)404
Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid)406
Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid)407
Error Code in Electrical System [E206] (Short-circuiting in travel speed shifting solenoid)408
Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid)409
Error Code in Electrical System [E213] (Disconnection in swing holding brake solenoid)410
Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)412
Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)413
Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid)414
Error Code in Electrical System [E217] (Abnormal input model code)416
Error Code in Electrical System [E218] (S-Net Comm Disc)418
Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid)420
Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system)421
Error Code in Electrical System [E224] (F Pump P Sensor Abnormality)422
Error Code in Electrical System [E225] (R Pump P Sensor Abnormality)424
Error Code in Electrical System [E226] (Press Sensor Power Abnormality)426
Error Code in Electrical System [E227] (Abnormality in engine rotation sensor)428
Error Code in Electrical System [E228] (Short-circuiting in attachment return switching relay)429
Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid)430
Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)432
Error Code in Electrical System [E238] (Disconnection in attachment return switching relay)434
Error Code in Electrical System [E245] (Short-circuiting in attachment oil flow rate adjusting EPC)436
Error Code in Electrical System [E246] (Disconnection in attachment oil flow rate adjusting EPC)437
Error Code in Electrical System [E247] (Arm IN PPC pressure sensor abnormality)438
Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)440
Error Code in Electrical System [E257] (Pump Abnormality)442
Error Code in Electrical System [E315] (Battery Relay Drive S/C)444
Error Code in Electrical System [E91B] (Engine Ne sensor problem)446
Error Code in Electrical System [E91C] (Engine G sensor problem)447
Error Code in Electrical System [E920] (Engine type selection error)448
Error Code in Electrical System [E921] (Engine type mismatch)450
Error Code in Electrical System [E931] (Fuel dial sys error)452
Error Code in Electrical System [E934] (Engine coolant sensor Hi error)454
Error Code in Electrical System [E936] (Engine oil press sw error)456
Error Code in Electrical System [E93C] (Engine boost sensor error)458
Error Code in Electrical System [E93D] (Engine fuel temp sensor error)460
Error Code in Electrical System [E953] (Engine Comm Abnormality)462
Error Code in Electrical System [E954] (Short engine starter sw)464
Error Code in Electrical System [E955] (Engine S-NET error)466
Error Code in Electrical System [E956] (Engine power failure (1))468
Error Code in Electrical System [E957] (Engine power failure (2))470
Error Code in Electrical System [E95A] (Engine Q-adj sw signal error)472
Error Code in Electrical System [E96A] (Engine coolant sensor Lo error)474
Error Code in Electrical System [E970] (PCV1 over current)476
Error Code in Electrical System [E971] (PCV2 over current)477
Error Code in Electrical System [E974] (PCV1 line cut)478
Error Code in Electrical System [E975] (PCV2 line cut)479
Error Code in Electrical System [E977] (Rail press sensor error)480
Error Code in Electrical System [E979] (Rail press high)482
Error Code in Electrical System [E97A] (Rail press abnormal)482
Error Code in Electrical System [E97B] (Rail press low)483
Error Code in Electrical System [E97C] (Rail press too low)485
Error Code in Electrical System [E97D] (Rail press out of control)485
Error Code in Electrical System [E980] (Eng Controller Abnormality)486
Error Code in Electrical System [E981] (Fuel Injector 1 Disc)488
Error Code in Electrical System [E982] (Fuel Injector 2 Disc)489
Error Code in Electrical System [E983] (Fuel Injector 3 Disc)490
Error Code in Electrical System [E984] (Fuel Injector 4 Disc)491
Error Code in Electrical System [E985] (Fuel Injector 5 Disc)492
Error Code in Electrical System [E986] (Fuel Injector 6 Disc)493
Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C)494
Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C)496
Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)498
Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard)498
Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging)500
Failure Code in Mechanical System [AB00KE] (Charge Voltage Low)502
Failure Code in Mechanical System [B@BAZG] (Eng Oil Press Low)504
Failure Code in Mechanical System [B@BAZK] (Eng Oil Level Low)506
Failure Code in Mechanical System [B@BCNS] (Eng Water Overheat)507
Failure Code in Mechanical System [B@BCZK] (Eng Water Lvl Low)508
Failure Code in Mechanical System [B@HANS] (Hydr Oil Overheat)509
20_501pdf 0
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)381
Before carrying out troubleshooting for electrical system (E-mode)512
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE513
E-1 The engine does not start (The engine does not rotate)514
E-2 Preheater does not operate518
E-3 Auto engine warm-up device does not work520
E-4 Auto-decelerator does not operate521
E-5 All work equipment, swing and travel do not move522
E-6 One-touch power max function does not operate524
E-7 Machine push-up function does not operate normally525
E-8 Attachment circuit does not change527
E-9 No display in monitor panel at all529
E-10 Part of display on monitor panel is missing530
E-11 Monitor panel displays contents irrelevant to the model530
E-12 Fuel level monitor red lamp lights up while engine is running531
E-13 Engine water temperature gauge does not display correctly532
E-14 Hydraulic oil temperature gauge does not display correctly534
E-15 Fuel gauge does not display correctly416
E-16 Swing lock monitor does not display correctly536
E-17 When monitor switch is operated, nothing is displayed538
E-18 Windshield wiper and window washer do not work540
E-19 Alarm buzzer cannot be cancelled544
E-20 “Boom RAISE” is not correctly displayed in monitor function545
E-21 “Boom LOWER” is not correctly displayed in monitor function546
E-22 “Arm IN” is not displayed normally in monitoring function547
E-23 “Arm DUMPING” is not correctly displayed in monitor function548
E-24 “Bucket CURL” is not displayed normally in monitoring function549
E-25 “Bucket DUMPING” is not correctly displayed in monitor function550
E-26 “Swing” is not displayed normally in monitoring function552
E-27 “TRAVEL” is not correctly displayed in monitor function554
E-28 “Travel Differential Pressure” is not correctly displayed in monitor function556
E-29 “Service” is not correctly displayed in monitor function558
E-30 Travel alarm does not sound or does not stop sounding560
E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM562
Troubleshooting by failure phenomenon569
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TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)381
system chart for hydraulic and mechanical system574
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE576
H-1 All work equipment lack power, or travel and swing speeds are slow577
H-2 Engine speed sharply drops or engine stalls550
H-3 No work equipment, travel or swing move558
H-4 Abnormal noise is heard from around hydraulic pump579
H-5 Auto-decelerator does not work580
H-6 Fine control mode does not function580
H-7 Boom moves slowly or lacks power581
H-8 Arm moves slowly or lacks power567
H-9 Bucket moves slowly or lacks power570
H-10 Work equipment does not move in its single operation583
H-11 Work equipment has a bit too fast hydraulic drift584
H-12 Work equipment has big time lag585
H-13 Other work equipment moves when relieving single circuit585
H-14 One-touch power max function does not work585
H-15 Machine push-up function does not work586
H-16 In compound operation, work equipment with larger load moves slowly587
H-17 In swing + boom RAISE operation, boom moves slowly587
H-18 In swing + travel, travel speed drops sharply587
H-19 Machine swerves in travel588
H-20 Machine travels slowly589
H-21 Machine cannot be easily steered or lacks power590
H-22 Travel speed does not shift, or it is slower or faster than preset speed591
H-23 Track shoe does not turn (on one side only)592
H-24 Machine does not swing593
H-25 Swing acceleration is poor, or swing speed is slow594
H-26 Excessive overrun when stopping swing595
H-27 There is big shock when stopping swing596
H-28 There is big abnormal noise caused when stopping swing596
H-29 Swing natural drift is too big597
H-30 Attachment circuit does not change598
H-31 Flow rate in attachment circuit cannot be adjusted598
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TROUBLESHOOTING OF ENGINE (S MODE)381
POINTS TO REMEMBER WHEN TROUBLESHOOTING600
METHOD OF USING TROUBLESHOOTING CHARTS521
S-1 Starting performance is poor (starting always takes time)604
S-2 Engine does not start605
S-3 Engine does not pick up smoothly (follow-up is poor)608
S-4 Engine stops during operations521
S-5 Engine does not rotate smoothly (hunting)610
S-6 Engine lacks output (or lacks power)611
S-7 Exhaust smoke is black (incomplete combustion)612
S-8 Oil consumption is excessive (or exhaust smoke is blue)613
S-9 Oil becomes contaminated quickly614
S-10 Fuel consumption is excessive615
S-11 Oil is in cooling water (or water spurts back, or water level goes down)616
S-12 Oil pressure caution lamp lights up (drop in oil pressure)522
S-13 Oil level rises (water, fuel in oil)618
S-14 Water temperature becomes too high (overheating)619
S-15 Abnormal noise is made620
S-16 Vibration is excessive621
SEC_30SERVERpdf 0
30 DISASSEMBLY AND ASSEMBLY623
HOW TO READ THIS MANUAL624
REMOVAL AND INSTALLATION OF ASSEMBLIES624
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES625
PRECAUTIONS WHEN PERFORMING OPERATION626
SPECIAL TOOL LIST628
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY635
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL642
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL646
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY649
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY652
REMOVAL AND INSTALLATION OF NOZZLE TIP655
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY657
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY658
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY660
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY662
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY667
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY668
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY669
REMOVAL AND INSTALLATION OF SPROCKET676
REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY677
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY678
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY685
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY687
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY688
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY691
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY693
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY695
REMOVAL AND INSTALLATION OF OPERATOR’S CAB697
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY700
REMOVAL AND INSTALLATION OF PUMP CONTROLLER701
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER702
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY703
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY706
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY707
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY709
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT712
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY713
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY716
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY720
DISASSEMBLY AND ASSEMBLY OF of CENTER SWIVEL JOINT ASSEMBLY722
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY723
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY724
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY725
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY730
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)733
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY743
90pdf 0
90 OTHERS 23
90-01pdf 0
HYDRAULIC CIRCUIT DIAGRAM (1/2)751
HYDRAULIC CIRCUIT DIAGRAM (2/2)753
ELECTRICAL CIRCUIT DIAGRAM (1/5)755
ELECTRICAL CIRCUIT DIAGRAM (2/5)757
ELECTRICAL CIRCUIT DIAGRAM (3/5)759
ELECTRICAL CIRCUIT DIAGRAM (4/5)761
ELECTRICAL CIRCUIT DIAGRAM (5/5)763
90-02pdf 0
AIR CONDITIONER ELECTRICAL CIRCUIT765

DESCRIPTION:

Komatsu PC450-7K PC450LC-7K Shop Manual – PDF DOWNLOAD

SERIAL NUMBER
K40001 AND UP
K40001 AND UP

GENERAL:

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.

MAINTENANCE STANDARD

This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in

STRUCTURE AND FUNCTION

OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

G.B 13/12/24