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KOMATSU PC450LC-7 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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Description
KOMATSU PC450LC-7 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC450LC-7 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 876
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC450LC-7 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
COVER.............................................................................................................................. 3 CONTENTS........................................................................................................................... 4 01 GENERAL......................................................................................................................... 38 SPECIFICATION DRAWINGS......................................................................................................... 39 SPECIFICATIONS................................................................................................................. 43 WEIGHT TABLE................................................................................................................... 49 FUEL, COOLANT AND LUBRICANTS................................................................................................... 53 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.................................................................................... 56 ENGINE RELATED PARTS........................................................................................................... 57 RADIATOR・OIL COOLER・AFTERCOOLER................................................................................................ 59 POWER TRAIN.................................................................................................................... 60 FINAL DRIVE.................................................................................................................... 61 SPROCKET....................................................................................................................... 63 SWING MACHINERY................................................................................................................ 65 SWING CIRCLE................................................................................................................... 67 TRACK FRAME AND RECOIL SPRING.................................................................................................. 68 IDLER.......................................................................................................................... 70 CARRIER ROLLER................................................................................................................. 72 TRACK ROLLER................................................................................................................... 73 TRACK SHOE..................................................................................................................... 74 HYDRAULIC PIPING DRAWING....................................................................................................... 78 HYDRAULIC TANK................................................................................................................. 80 HYDRAULIC PUMP................................................................................................................. 81 LS(PC)-EPC VALVE...............................................................................................................100 VARIABLE VOLUME VALVE..........................................................................................................103 CONTROL VALVE..................................................................................................................105 CLSS...........................................................................................................................129 FUNCTIONS AND OPERATION BY VALVE...............................................................................................133 ATTACHMENT CIRCUIT SELECTOR VALVE..............................................................................................175 HOLDING VALVE..................................................................................................................177 SWING MOTOR....................................................................................................................183 REVERSAL PREVENTION VALVE......................................................................................................188 CENTER SWIVEL JOINT............................................................................................................190 TRAVEL MOTOR...................................................................................................................191 VALVE CONTROL..................................................................................................................202 TRAVEL PPC SHUTTLE VALVE.......................................................................................................203 WORK EQUIPMENT・SWING PPC VALVE.................................................................................................207 TRAVEL PPC VALVE...............................................................................................................211 SERVICE PPC VALVE..............................................................................................................218 SOLENOID VALVE.................................................................................................................219 PPC ACCUMULATOR................................................................................................................221 RETURN OIL FILTER..............................................................................................................222 HYDRAULIC CYLINDER.............................................................................................................223 WORK EQUIPMENT.................................................................................................................227 AIR CONDITIONER................................................................................................................235 ENGINE CONTROL.................................................................................................................236 ELECTRONIC CONTROL SYSTEM......................................................................................................241 MONITOR SYSTEM.................................................................................................................268 7-SEGMENT MONITOR SYSTEM.......................................................................................................289 SENSOR.........................................................................................................................296 20 TESTING AND ADJUSTING...........................................................................................................299 STANDARD VALUE TABLE FOR ENGINE................................................................................................300 STANDARD VALUE TABLE FOR CHASSIS (BACKHOE SPECIFICATION).......................................................................301 STANDARD VALUE TABLE FOR CHASSIS (LOADING SHOVEL SPECIFICATION)................................................................310 TESTING AND ADJUSTING..........................................................................................................319 TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE........................................................................320 MEASURING ENGINE SPEED.....................................................................................................322 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).............................................................................323 MEASURING EXHAUST TEMPERATURE..............................................................................................324 MEASURING EXHAUST GAS COLOR................................................................................................325 ADJUSTING VALVE CLEARANCE..................................................................................................326 MEASURING COMPRESSION PRESSURE.............................................................................................328 MEASURING BLOW-BY PRESSURE.................................................................................................330 MEASURING ENGINE OIL PRESSURE..............................................................................................331 HANDLING OF FUEL SYSTEM DEVICES............................................................................................332 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM...............................................................................332 MEASURING FUEL PRESSURE....................................................................................................333 BLEEDING AIR FROM FUEL CIRCUIT.............................................................................................334 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE.....................................................................................336 ADJUSTING ENGINE SPEED SENSOR..............................................................................................337 TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION.................................................................338 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION..............................................................339 MEASURING CLEARANCE OF SWING CIRCLE BEARING................................................................................340 TESTING AND ADJUSTING TRACK SHOE TENSION...................................................................................341 TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...........................................342 MEASURING BASIC PRESSURE IN CONTROL CIRCUIT................................................................................346 TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT..............................................................347 TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT..............................................................350 MEASURING SOLENOID VALVE OUTPUT PRESSURE...................................................................................355 MEASURING PPC VALVE OUTPUT PRESSURE........................................................................................358 ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES......................................................................360 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT................................................................361 RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT...........................................................................363 MEASURING OIL LEAKAGE......................................................................................................364 BLEEDING AIR FROM EACH PART................................................................................................367 TESTING PROCEDURE OF DIODE.................................................................................................370 SPECIAL FUNCTIONS OF MONITOR PANEL.........................................................................................371 SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL..............................................................................398 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER......................................................................417 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM.......................................................418 PM-CLINIC SERVICE..........................................................................................................420 TROUBLESHOOTING................................................................................................................427 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................428 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................................................429 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...........................................................................430 CHECKS BEFORE TROUBLESHOOTING..............................................................................................438 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...............................................................................439 CONNECTOR ARRANGEMENT DIAGRAM AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM..................................................443 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................................460 T- BRANCH BOX AND T- BRANCH ADAPTER TABLE..................................................................................496 CONNECTION TABLE OF FUSE BOX...............................................................................................499 TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED.....................500 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.........................................................................502 ERROR CODE IN ELECTRICAL SYSTEM [E112](SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE).....504 ERROR CODE IN ELECTRICAL SYSTEM [E113](SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)....506 ERROR CODE IN ELECTRICAL SYSTEM [E114](SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM).................................508 ERROR CODE IN ELECTRICAL SYSTEM [E115](ABNORMAL WINDSHIELD WIPER MOTION)...............................................510 ERROR CODE IN ELECTRICAL SYSTEM [E116](ABNORMALITY IN RETRACTING WINDSHIELD WIPER) ....................................512 ERROR CODE IN ELECTRICAL SYSTEM (E117](ENG. CONTROLLER S-NET COMM. ERR.)...............................................514 ERROR CODE IN ELECTRICAL SYSTEM (E118](PUMP CONTROLLER S-NET COMM. ERR.)...............................................516 ERROR CODE IN ELECTRICAL SYSTEM (E128](MONITOR COMM. ABNORMALITY)......................................................518 ERROR CODE IN ELECTRICAL SYSTEM (E201](SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)...............................520 ERROR CODE IN ELECTRICAL SYSTEM [E203](SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)...............................521 ERROR CODE IN ELECTRICAL SYSTEM [E204](SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)......................................523 ERROR CODE IN ELECTRICAL SYSTEM [E205](SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)....................................524 ERROR CODE IN ELECTRICAL SYSTEM [E206](SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID).............................525 ERROR CODE IN ELECTRICAL SYSTEM [E211](DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)..................................526 ERROR CODE IN ELECTRICAL SYSTEM [E213](DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)..................................527 ERROR CODE IN ELECTRICAL SYSTEM [E214](DISCONNECTION OF MERGE/DIVIDE SOLENOID).........................................529 ERROR CODE IN ELECTRICAL SYSTEM [E215](DISCONNECTION IN 2-STAGE RELIEF SOLENOID).......................................530 ERROR CODE IN ELECTRICAL SYSTEM [E216](DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)................................531 ERROR CODE IN ELECTRICAL SYSTEM [E217](ABNORMAL INPUT MODEL CODE)......................................................532 ERROR CODE IN ELECTRICAL SYSTEM [E218](S-NET COMM. DISC.)..............................................................534 ERROR CODE IN ELECTRICAL SYSTEM [E222](SHORT-CIRCUITING IN LS-EPC SOLENOID)............................................536 ERROR CODE IN ELECTRICAL SYSTEM [E223](DISCONNECTION IN LS-EPC SOLENOID SYSTEM)........................................537 ERROR CODE IN ELECTRICAL SYSTEM [E224](F PUMP P. SENSOR ABNORMALITY)...................................................538 ERROR CODE IN ELECTRICAL SYSTEM [E225](R PUMP P. SENSOR ABNORMALITY)...................................................540 ERROR CODE IN ELECTRICAL SYSTEM [E226](P. SENSOR POWER ABNORMALITY)....................................................542 ERROR CODE IN ELECTRICAL SYSTEM [E227](ABNORMALITY IN ENGINE ROTATION SENSOR) .........................................544 ERROR CODE IN ELECTRICAL SYSTEM [E228](SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)..........................545 ERROR CODE IN ELECTRICAL SYSTEM [E232](SHORT-CIRCUITING IN PC-EPC SOLENOID)............................................546 ERROR CODE IN ELECTRICAL SYSTEM [E233](DISCONNECTION IN PC-EPC SOLENOID SYSTEM)........................................548 ERROR CODE IN ELECTRICAL SYSTEM [E238](DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY).............................550 ERROR CODE IN ELECTRICAL SYSTEM [E245](SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC).....................552 ERROR CODE IN ELECTRICAL SYSTEM [E246](DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)........................553 ERROR CODE IN ELECTRICAL SYSTEM [E247](ARM IN PPC PRESSURE SENSOR ABNORMALITY).........................................554 ERROR CODE IN ELECTRICAL SYSTEM [E248](BUCKET CURL PPC PRESSURE SENSOR ABNORMALITY)....................................556 ERROR CODE IN ELECTRICAL SYSTEM [E257](PUMP ABNORMALITY)...............................................................558 ERROR CODE IN ELECTRICAL SYSTEM [E315](BATTERY RELAY DRIVE S/C)........................................................560 ERROR CODE IN ELECTRICAL SYSTEM [E91B](ENGINE NE SENSOR PROBLEM).......................................................562 ERROR CODE IN ELECTRICAL SYSTEM [E91C](ENGINE G SENSOR PROBLEM)........................................................563 ERROR CODE IN ELECTRICAL SYSTEM [E920](ENGINE TYPE SELECTION ERROR)....................................................564 ERROR CODE IN ELECTRICAL SYSTEM [E921](ENGINE TYPE MISMATCH)...........................................................566 ERROR CODE IN ELECTRICAL SYSTEM [E931](FUEL DIAL SYS. ERROR)...........................................................567 ERROR CODE IN ELECTRICAL SYSTEM [E934](ENGINE COOLANT SENSOR HI ERROR).................................................569 ERROR CODE IN ELECTRICAL SYSTEM [E936](ENGINE OIL PRESS. SW. ERROR)....................................................571 ERROR CODE IN ELECTRICAL SYSTEM [E93C](ENGINE BOOST SENSOR ERROR)......................................................573 ERROR CODE IN ELECTRICAL SYSTEM [E93D](ENGINE FUEL TEMP. SENSOR ERROR).................................................575 ERROR CODE IN ELECTRICAL SYSTEM [E953](ENGINE COMM. ABNORMALITY).......................................................577 ERROR CODE IN ELECTRICAL SYSTEM [E954](SHORT ENGINE STARTER SW.).......................................................579 ERROR CODE IN ELECTRICAL SYSTEM [E955](ENGINE S-NET ERROR).............................................................581 ERROR CODE IN ELECTRICAL SYSTEM [E956](ENGINE POWER FAILURE (1)).......................................................583 ERROR CODE IN ELECTRICAL SYSTEM [E957](ENGINE POWER FAILURE (2)).......................................................585 ERROR CODE IN ELECTRICAL SYSTEM [E95A](ENGINE Q-ADJ. SW. SIGNAL ERROR).................................................587 ERROR CODE IN ELECTRICAL SYSTEM [E96A](ENGINE COOLANT SENSOR LO ERROR).................................................588 ERROR CODE IN ELECTRICAL SYSTEM [E970](PCV1 OVER CURRENT)..............................................................590 ERROR CODE IN ELECTRICAL SYSTEM [E971](PCV2 OVER CURRENT)..............................................................591 ERROR CODE IN ELECTRICAL SYSTEM [E974](PCV1 LINE CUT)..................................................................592 ERROR CODE IN ELECTRICAL SYSTEM [E975](PCV2 LINE CUT)..................................................................593 ERROR CODE IN ELECTRICAL SYSTEM [E977](RAIL PRESS. SENSOR ERROR).......................................................594 ERROR CODE IN ELECTRICAL SYSTEM [E979](RAIL PRESS. HIGH)...............................................................596 ERROR CODE IN ELECTRICAL SYSTEM [E97A](RAIL PRESS. ABNORMAL)...........................................................596 ERROR CODE IN ELECTRICAL SYSTEM [E97B](RAIL PRESS. LOW)................................................................597 ERROR CODE IN ELECTRICAL SYSTEM [E97C](RAIL PRESS. TOO LOW)............................................................599 ERROR CODE IN ELECTRICAL SYSTEM [E97D](RAIL PRESS. CUT OF CONTROL).....................................................599 ERROR CODE IN ELECTRICAL SYSTEM [E980](ENG. CONTROLLER ABNORMALITY)....................................................600 ERROR CODE IN ELECTRICAL SYSTEM [E981](FUEL INJECTOR 1 DISC.)..........................................................602 ERROR CODE IN ELECTRICAL SYSTEM [E982](FUEL INJECTOR 2 DISC.)..........................................................603 ERROR CODE IN ELECTRICAL SYSTEM [E983](FUEL INJECTOR 3 DISC.)..........................................................604 ERROR CODE IN ELECTRICAL SYSTEM [E984](FUEL INJECTOR 4 DISC.)..........................................................605 ERROR CODE IN ELECTRICAL SYSTEM [E985](FUEL INJECTOR 5 DISC.)..........................................................606 ERROR CODE IN ELECTRICAL SYSTEM [E986](FUEL INJECTOR 6 DISC.)..........................................................607 ERROR CODE IN ELECTRICAL SYSTEM [E98A](FUEL INJECTOR 1-3 S/C)..........................................................608 ERROR CODE IN ELECTRICAL SYSTEM [E98B](FUEL INJECTOR 4-6 S/C)..........................................................610 ERROR CODE IN MECHANICAL SYSTEM [A000N1](ENGINE HIGH-IDLING SPEED OUT OF STANDARD).....................................612 ERROR CODE IN MECHANICAL SYSTEM [A000N2](ENGINE LOW-IDLING SPEED OUT OF STANDARD)......................................612 FAILURE CODE IN MECHANICAL SYSTEM [AA10NX](AIRCLEANER CLOGGING.........................................................613 FAILURE CODE IN MECHANICAL SYSTEM [AB00KE](CHARGE VOLTAGE LOW).........................................................615 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG](ENG. OIL PRESS. LOW)........................................................617 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK](ENG. OIL LEVEL LOW).........................................................619 FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS](ENG. WATER OVERHEAT)........................................................620 FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK](ENG. WATER LVL LOW).........................................................621 FAILURE CODE IN MECHANICAL SYSTEM [B@HANS](HYDR. OIL OVERHEAT).........................................................622 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..............................................................................623 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.........................................................................625 E-1 ENGINE DOES NOT START(THE ENGINE DOES NOT ROTATE)..................................................................626 E-2 PREHEATER DOES NOT OPERATE.........................................................................................629 E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK...........................................................................631 E-4 AUTO-DECELERATOR DOES NOT OPERATE..................................................................................632 E-5 ALL WORK EQUIPMENT,SWING AND TRAVEL DO NOT MOVE....................................................................633 E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE.....................................................................635 E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY.................................................................636 E-8 ATTACHMENT CIRCUIT DOES NOT CHANGE.................................................................................638 E-9 NO DISPLAY IN MONITOR PANEL AT ALL.................................................................................640 E-10 PART OF DISPLAY ON MONITOR PANEL IS MISSING.......................................................................641 E-11 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL...........................................................641 E-12 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING.....................................................642 E-13 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.........................................................643 E-14 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY........................................................645 E-15 FUEL GAUGE DOES NOT DISPLAY CORRECTLY.............................................................................646 E-16 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY.....................................................................647 E-17 WHEN MONITOR SWITCH IS OPERATED,NOTHING IS DISPLAYED..............................................................649 E-18 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK....................................................................651 E-19 ALARM BUZZER CANNOT BE CANCELLED..................................................................................655 E-20 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................656 E-21 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................657 E-22 "ARM IN" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION.........................................................658 E-23 "ARM DUMPING " IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....................................................659 E-24 "BUCKET CURL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION....................................................660 E-25 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...................................................661 E-26 "SWING" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION..........................................................662 E-27 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...........................................................664 E-28 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....................................666 E-29 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................................................668 E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING.............................................................670 E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM........................................................................672 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H MODE).................................................................683 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM.......................................................................684 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.........................................................................686 H-1 ALL WORK EQUIPMENT LACK POWER,OR TRAVEL AND SWING SPEEDS ARE SLOW..................................................687 H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS........................................................................688 H-3 NO WORK EQUIPMENT,TRAVEL OR SWING MOVE.............................................................................689 H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP.................................................................689 H-5 AUTO-DECELERATOR DOES NOT WORK.....................................................................................690 H-6 FINE CONTROL MODE DOES NOT FUNCTION................................................................................690 H-7 BOOM MOVES SLOWLY OR LACKS POWER...................................................................................691 H-8 ARM MOVES SLOWLY OR LACKS POWER....................................................................................692 H-9 BUCKET MOVES SLOWLY OR LACKS POWER.................................................................................693 H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION..............................................................693 H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT.................................................................694 H-12 WORK EQUIPMENT HAS BIG TIME LAG...................................................................................695 H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT..........................................................695 H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK.......................................................................695 H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK............................................................................696 H-16 IN COMPOUND OPERATION,WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY................................................697 H-17 IN SWING + BOOM RAISE OPERATION,BOOM MOVES SLOWLY.................................................................697 H-18 IN SWING + TRAVEL,TRAVEL SPEED DROPS SHARPLY......................................................................697 H-19 MACHINE SWERVES IN TRAVEL.........................................................................................698 H-20 MACHINE TRAVELS SLOWLY............................................................................................699 H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER...................................................................700 H-22 TRAVEL SPEED DOES NOT SHIFT,OR IT IS SLOWER OR FASTER THAN PRESET SPEED...........................................701 H-23 TRACK SHOE DOES NOT TURN(ON ONE SIDE ONLY)........................................................................702 H-24 MACHINE DOES NOT SWING............................................................................................703 H-25 SWING ACCELERATION IS POOR,OR SWING SPEED IS SLOW.................................................................704 H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING.............................................................................705 H-27 THERE IS BIG SHOCK WHEN STOPPING SWING............................................................................706 H-28 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING............................................................706 H-29 SWING NATURAL DRIFT IS TOO BIG....................................................................................707 H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE................................................................................708 H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED................................................................708 TROUBLESHOOTING OF ENGINE (S MODE).........................................................................................709 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................710 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................711 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..........................................................714 S-2 ENGINE DOES NOT START..............................................................................................715 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)................................................................718 S-4 ENGINE STOPS DURING OPERATIONS.....................................................................................719 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)...........................................................................720 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...............................................................................721 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)......................................................................722 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)............................................................723 S-9 OIL BECOMES CONTAMINATED QUICKLY...................................................................................724 S-10 FUEL CONSUMPTION IS EXCESSIVE.....................................................................................725 S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)..........................................726 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)........................................................727 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...............................................................................728 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)...................................................................729 S-15 ABNORMAL NOISE IS MADE............................................................................................730 S-16 VIBRATION IS EXCESSIVE............................................................................................731 30 DISASSEMBLY AND ASSEMBLY........................................................................................................732 HOW TO READ THIS MANUAL........................................................................................................733 COATING MATERIALS LIST.........................................................................................................735 SPECIAL TOOL LIST..............................................................................................................738 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.............................................................................748 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL...................................................................................755 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL..................................................................................759 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY..........................................................................762 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY.............................................................................765 REMOVAL AND INSTALLATION OF NOZZLE TIP.........................................................................................768 REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY............................................................................770 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY..................................................................................771 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY......................................................................773 REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY.................................................................775 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY..............................................................................780 REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...........................................................781 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...........................................................782 REMOVAL AND INSTALLATION OF SPROCKET...........................................................................................789 REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY..............................................................790 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY...............................................................................791 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY............................................................................798 DISASSEMBLY AND ASSEMBLY OF TRAVEL ROLLER ASSEMBLY.............................................................................800 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY.....................................................................................801 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY.............................................................................804 EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY..............................................................................806 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY......................................................................808 REMOVAL AND INSTALLATION OF OPERATOR'S CAB.....................................................................................810 REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY...................................................................................813 REMOVAL AND INSTALLATION OF PUMP CONTROLLER....................................................................................814 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER..................................................................................815 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY...........................................................................816 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY.............................................................................819 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY............................................................................820 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY............................................................................822 REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT.............................................................825 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY.............................................................................826 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY.............................................................................829 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY.......................................................................833 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY.......................................................................835 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................836 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY..........................................................................838 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY........................................................................840 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY............................................................................845 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS).................................................................848 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY..............................................................................858 90 OTHERS..........................................................................................................................864 HYDRAULIC CIRCUIT DIAGRAM (1/2)................................................................................................866 HYDRAULIC CIRCUIT DIAGRAM (2/2)................................................................................................867 ELECTRICAL CIRCUIT DIAGRAM (1/6)...............................................................................................868 ELECTRICAL CIRCUIT DIAGRAM (2/6)...............................................................................................869 ELECTRICAL CIRCUIT DIAGRAM (3/6)...............................................................................................870 ELECTRICAL CIRCUIT DIAGRAM (4/6)...............................................................................................871 ELECTRICAL CIRCUIT DIAGRAM (5/6)...............................................................................................872 ELECTRICAL CIRCUIT DIAGRAM (6/6)...............................................................................................873 AIR CONDITIONER ELECTRICAL CIRCUIT.............................................................................................874 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)...........................................................................................875 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE).............................................................................876 Blank Page......................................................................................................................... 2
DESCRIPTION:
KOMATSU PC450LC-7 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD
This section explains the safety and basic information.
01. GENERAL
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume)
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
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