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Komatsu PC450LC-8 Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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Komatsu PC450LC-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS : PC450LC-8 A10001 and up
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Description
Komatsu PC450LC-8 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC450LC-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC490LC-8
Serial Number: A40001 and up
Book Code: CEBM007602
Language: English
Pages: 1129
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC450LC-8 Hydraulic Excavator Shop Manual
1 GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
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 gives the judgement standards when inspecting disassembled parts.
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 checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
AIR CONDITIONING
Structure, function, testing, adjusting, and troubleshooting of air conditioning system.
DIAGRAMS AND DRAWINGS
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu PC450LC-8 Hydraulic Excavator Shop Manual
CEBM007602 - PC450LC-8 sn A10001 and up..................................................... 1 CONTENTS................................................................................. 2 REVISED PAGES............................................................................ 3 SAFETY................................................................................... 13 Safety Notice........................................................................ 13 Important Safety Notice.......................................................... 13 General Precautions.............................................................. 13 Preparations For Work............................................................ 13 Precautions During Work.......................................................... 13 GENERAL.................................................................................. 16 HOW TO READ THE SHOP MANUAL.............................................................. 17 Volumes.............................................................................. 17 Distribution And Updating............................................................ 17 Filing Method........................................................................ 17 Revised Edition Mark................................................................. 17 Revisions............................................................................ 17 Symbols.............................................................................. 17 HOISTING INSTRUCTIONS.................................................................... 18 Hoisting............................................................................. 18 Wire Ropes........................................................................... 18 PUSH PULL COUPLER........................................................................ 19 Type 1............................................................................... 19 Disconnection.................................................................... 19 Connection....................................................................... 19 Type 2............................................................................... 20 Disconnection.................................................................... 20 Connection....................................................................... 20 Type 3............................................................................... 21 Disconnection.................................................................... 21 Connection....................................................................... 21 EXPLANATION OF MAINTENANCE STANDARD TERMS................................................ 22 STANDARD TIGHTENING TORQUE............................................................... 24 Bolts And Nuts....................................................................... 24 Tightening Torque Of Hose Nuts....................................................... 25 Tightening Torque Of Split Flange Bolts.............................................. 25 Tightening Torque For Flared Nuts.................................................... 25 Tightening Torques For O-ring Boss Piping Joints..................................... 26 Table Of Tightening Torques For O-ring Boss Plugs.................................... 26 Torque Table For Hoses (Taper Seal Type And Face Seal Type).......................... 26 ELECTRIC WIRE CODE....................................................................... 27 Classification By Thickness.......................................................... 27 Classification By Color And Code..................................................... 27 How To Read Electric Wire Code....................................................... 28 CONVERSION TABLES........................................................................ 31 Method Of Using The Conversion Table................................................. 31 COATING MATERIALS........................................................................ 37 01 GENERAL................................................................................... 39 SPECIFICATION DIMENSION DRAWINGS......................................................... 40 Dimensions........................................................................... 40 Working Ranges....................................................................... 41 SPECIFICATIONS........................................................................... 42 WEIGHT TABLE............................................................................. 46 FUEL, COOLANT AND LUBRICANTS............................................................. 48 Lubrication Chart.................................................................... 50 10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD............................................... 51 ENGINE AND COOLING SYSTEM................................................................ 54 Engine Related Parts................................................................. 54 Radiator, Oil Cooler and Aftercooler................................................. 55 POWER TRAIN.............................................................................. 57 Power Train.......................................................................... 57 Final Drive.......................................................................... 58 Sprocket............................................................................. 60 Swing Machinery...................................................................... 62 Swing Circle......................................................................... 64 UNDERCARRIAGE AND FRAME.................................................................. 66 Track Frame and Recoil Spring........................................................ 66 Idler................................................................................ 68 Carrier Roller....................................................................... 70 Track Roller......................................................................... 72 Track Shoe........................................................................... 74 Triple Grouser Shoe.................................................................. 76 HYDRAULIC SYSTEM......................................................................... 78 Hydraulic Piping Drawing............................................................. 78 Hydraulic Tank and Filter............................................................ 80 Hydraulic Pump....................................................................... 82 LS Valve......................................................................... 88 PC Valve............................................................................. 93 LS(PC)-EPC Valve................................................................. 101 Variable Volume Valve............................................................ 104 Control Valve........................................................................ 106 CLSS (Closed Center Load Sensing System)............................................. 118 Functions and Operation by Valve..................................................... 122 Unload Valve..................................................................... 124 LS Bypass Valve.................................................................. 127 Pressure Compensation Valve...................................................... 128 Pressure Compensation Valve Inner Shuttle Valve.................................. 131 Boom Regeneration Circuit........................................................ 133 Arm Regeneration Circuit......................................................... 135 Merge-Divider Valve.............................................................. 137 LS Select Valve.................................................................. 139 Self Pressure Reducing Valve..................................................... 140 Travel Junction Valve............................................................ 143 Travel PPC Shuttle Valve......................................................... 145 Boom Drift Preventive Valve...................................................... 147 Arm Drift Preventive Valve....................................................... 150 Quick Return Valve............................................................... 154 Lift Check Valve................................................................. 156 Main Relief Valve................................................................ 157 2-Stage Safety-Suction Valve..................................................... 158 Variable Pressure Compensation Valve............................................. 160 Attachment Circuit Selector Valve................................................ 162 Holding Valve.................................................................... 164 Valve Control........................................................................ 169 PPC Valve........................................................................ 170 Travel PPC Valve................................................................. 176 Service PPC Valve (With EPC Valve)............................................... 186 Solenoid Valve................................................................... 188 PPC Accumulator.................................................................. 190 Return Oil Filter................................................................ 191 Center Swivel Joint.............................................................. 192 Travel Motor..................................................................... 194 Brake Valve...................................................................... 202 Swing Motor...................................................................... 208 Reverse Prevention Valve......................................................... 214 Hydraulic Cylinder................................................................... 218 Boom Cylinder.................................................................... 218 Arm Cylinder..................................................................... 218 Bucket Cylinder.................................................................. 218 WORK EQUIPMENT........................................................................... 220 Work Equipment....................................................................... 220 Dimensions Of Components............................................................. 222 Dimension Of Arm................................................................. 222 Dimension Of Bucket.............................................................. 224 AIR CONDITIONER PIPING................................................................... 226 ELECTRICAL SYSTEM........................................................................ 227 Engine Control....................................................................... 227 Fuel Control Dial................................................................ 229 Engine Controller................................................................ 230 Sensors.............................................................................. 234 Rotation Sensor.................................................................. 234 Oil Pressure Switch.............................................................. 234 Ambient Pressure Sensor.......................................................... 235 Boost Pressure Sensor............................................................ 235 Boost Temperature Sensor......................................................... 236 Coolant Temperature Sensor....................................................... 236 Hydraulic Oil Temperature Sensor................................................. 236 EGR Valve Stroke Sensor.......................................................... 237 Engine Oil Level Sensor.......................................................... 238 ELECTRONIC CONTROL SYSTEM................................................................ 239 Engine And Pump Composite Control Function........................................... 242 Pump and Valve Control............................................................... 248 2-Stage Relief Function.......................................................... 249 Power Maximizing and Machine Push-up................................................. 250 Auto-Deceleration.................................................................... 252 Auto-Warm-Up and Overheat Prevention................................................. 254 Swing Control........................................................................ 256 Travel Control....................................................................... 258 Attachment Flow Control and Circuit Selector......................................... 260 System Component Parts............................................................... 261 PPC Oil Pressure Switch.......................................................... 261 Oil Pressure Sensor.............................................................. 262 Pump Pressure Sensor (High Pressure)............................................. 263 Pump Controller.................................................................. 264 MONITOR SYSTEM........................................................................... 267 Machine Monitor...................................................................... 268 Monitor Control, Display Portion................................................. 272 Monitor Items And Display........................................................ 274 Switches......................................................................... 278 Komtrax Logic.................................................................... 289 Sensors.......................................................................... 296 KOMTRAX TERMINAL SYSTEM.................................................................. 299 Komtrax Communication Modem - TH300.................................................. 300 20 STANDARD VALUE TABLES..................................................................... 303 STANDARD VALUE TABLES.................................................................... 304 Engine Related....................................................................... 304 Chassis Related...................................................................... 305 30 TESTING AND ADJUSTING..................................................................... 313 SERVICE TOOLS............................................................................ 315 Sketches of Special Tools............................................................ 320 ENGINE................................................................................... 321 Engine Speed......................................................................... 321 Air Boost Pressure................................................................... 323 Exhaust Temperature.................................................................. 324 Exhaust Gas Color.................................................................... 325 Valve Clearance...................................................................... 327 Compression Pressure................................................................. 329 Blow-By Pressure..................................................................... 332 Engine Oil Pressure.................................................................. 333 EGR Valve Drive Pressure............................................................. 334 Handling Fuel System Parts........................................................... 335 Releasing Residual Pressure From Fuel System......................................... 335 Fuel Pressure........................................................................ 336 Cylinder Cut-Out Operation........................................................... 337 No Injection Cranking Operation...................................................... 337 Fuel Return Rate and Leakage......................................................... 338 Bleeding Air from Fuel Circuit....................................................... 341 Fuel Circuit, Checking for Leakage................................................... 343 FAN BELT AND ALTERNATOR BELT TENSION..................................................... 344 AIR CONDITIONER COMPRESSOR BELT TENSION.................................................. 345 SWING CIRCLE BEARING CLEARANCE........................................................... 346 TRACK SHOE TENSION....................................................................... 347 OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................... 348 CONTROL CIRCUIT - BASIC PRESSURE......................................................... 354 PUMP PC CONTROL CIRCUIT.................................................................. 355 PUMP LS CONTROL CIRCUIT.................................................................. 359 SOLENOID VALVE - OUTPUT PRESSURE......................................................... 364 PPC VALVE - OUTPUT PRESSURE.............................................................. 367 WORK EQUIPMENT PPC VALVE AND SWING PPC VALVE - PLAY ADJUSTMENT........................... 369 WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE................................................. 370 HYDRAULIC CIRCUIT - RELEASING REMAINING PRESSURE......................................... 372 Oil Leakage Measurement.............................................................. 373 BLEEDING AIR FROM VARIOUS PARTS.......................................................... 376 MACHINE MONITOR - SPECIAL FUNCTIONS...................................................... 379 Ordinary Functions and Special Functions of Machine Monitor.......................... 381 Operator Mode (Outline).............................................................. 383 Display of Komatsu Logo.......................................................... 384 Display of Inputting Password.................................................... 384 Display of Check of Breaker Mode................................................. 385 Display of Check Before Starting................................................. 385 Display of Warning after Check Before Starting................................... 385 Display of Ending of Maintenance Interval........................................ 386 Display of Check of Working Mode and Travel Speed................................ 386 Display of Ordinary Screen....................................................... 386 Display of End Screen............................................................ 387 Selection of Auto-Deceleration................................................... 387 Selection of Working Mode........................................................ 387 Selection of Travel Speed........................................................ 388 Operation to stop Alarm Buzzer................................................... 388 Operation of Windshield Wiper.................................................... 389 Operation of Window Washer....................................................... 389 Operation of Air Conditioner/Heater.............................................. 389 Operation to Display Camera Mode (If camera is installed)........................ 390 Operation to Display Clock and Service Meter..................................... 391 Check of Maintenance Information................................................. 391 Setting and Display of User Mode................................................. 391 KOMTRAX Message.................................................................. 392 Display of Energy-Saving Guidance................................................ 392 Display of Caution Monitor....................................................... 392 Display of Automatic Judgment of Breaker......................................... 393 Display of User Code and Failure Code............................................ 393 Function of Checking Display of LCD (Liquid Crystal Display)..................... 395 Function of Checking Service Meter............................................... 395 Function of Changing Attachment/Maintenance Password............................. 396 Service Mode......................................................................... 399 Monitoring....................................................................... 401 Abnormality Record (Mechanical Systems).......................................... 405 Abnormality Record (Electrical Systems).......................................... 406 Abnormality Record (Air-Conditioning System/Heater System)....................... 412 Maintenance Record............................................................... 413 Maintenance Mode Change.......................................................... 414 Phone Number Entry............................................................... 417 Default (Key-On Mode)............................................................ 418 Default (Unit)................................................................... 419 Default (With/Without Attachment)................................................ 420 Default (Attachment/Maintenance Password)........................................ 421 Default (Camera)................................................................. 422 Default (ECO Display)............................................................ 423 Default (Breaker Detect)......................................................... 425 Adjustment (Pump Absorption Torque (F)).......................................... 426 Adjustment (Low Speed)........................................................... 427 Adjustment (Attachment Flow Adjustment).......................................... 428 Determining a Defective Cylinder................................................. 429 Cylinder Cut-Out................................................................. 430 No Injection..................................................................... 431 Fuel Consumption................................................................. 433 KOMTRAX Settings (Terminal Status)............................................... 434 Long Distance Transport Mode..................................................... 435 KOMTRAX Settings (GPS & Communication Status).................................... 437 KOMTRAX Setting (Modem S/N: TH300)............................................... 438 Display of KOMTRAX Message....................................................... 439 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER............................................ 440 PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM................................ 441 DIODE INSPECTION PROCEDURES.............................................................. 446 PM CLINIC SERVICE........................................................................ 447 40 TROUBLESHOOTING........................................................................... 457 FAILURE CODES TABLE...................................................................... 461 FUSE LOCATIONS........................................................................... 464 Connection Table of Fuse Box......................................................... 464 Location of Fuse Box and Fuse Numbers................................................ 465 GENERAL INFORMATION...................................................................... 468 Points to Remember when Troubleshooting.............................................. 468 Sequence of Events in Troubleshooting................................................ 470 Handling Electric Equipment and Hydraulic Components................................. 471 Connectors newly used for Tier 3 Engines............................................. 479 Checks before Troubleshooting........................................................ 483 Classification and Troubleshooting Steps............................................. 484 Classification of Troubleshooting................................................ 484 Information in Troubleshooting Table............................................. 486 Possible Problems and Troubleshooting No......................................... 488 Connection Table for Connector Pin Numbers........................................... 491 T-adapter Box and T-adapter Table.................................................... 526 FAILURE CODE (DISPLAY OF CODE)........................................................... 529 989L00 - Engine Controller Lock Caution 1............................................ 529 989M00 - Engine Controller Lock Caution 2............................................ 529 989N00 - Engine Controller Lock Caution 3............................................ 530 AA10NX - Air Cleaner Clogging........................................................ 532 AB00KE - Charge Voltage Low.......................................................... 534 B@BAZG - Engine Oil Pressure Low..................................................... 536 B@BAZK - Engine Oil Level Low........................................................ 538 B@BCNS - Engine Coolant Overheat..................................................... 540 B@BCZK - Engine Coolant Level Low.................................................... 542 B@HANS - Hydraulic Oil Overheat...................................................... 544 CA111 - EMC Critical Internal Failure................................................ 546 CA115 - Engine Ne And Bkup Speed Sensor Error........................................ 548 CA122 - Charge Air Pressure Sensor High Error........................................ 550 CA123 - Charge Air Pressure Sensor Low Error......................................... 552 CA131 - Throttle Sensor High Error................................................... 554 CA132 - Throttle Sensor Low Error.................................................... 556 CA135 - Engine Oil Pressure Sensor High Error........................................ 558 CA141 - Engine Oil Pressure Sensor Low Error......................................... 560 CA144 - Coolant Temperature Sensor High Error........................................ 562 CA145 - Coolant Temperature Sensor Low Error......................................... 564 CA153 - Charge Air Temperature Sensor High Error..................................... 566 CA154 - Charge Air Temperature Sensor Low Error...................................... 568 CA187 - Sensor Power Supply 2 Volt Low Error......................................... 570 CA221 - Ambient Pressure Sensor High Error........................................... 572 CA222 - Ambient Pressure Sensor Low Error............................................ 574 CA227 - Sensor Supply 2 Volt High Error.............................................. 576 CA234 - Engine Overspeed............................................................. 578 CA238 - NE Speed Sensor Supply Voltage Error......................................... 579 CA263 - Fuel Temperature Sensor High Error........................................... 580 CA265 - Fuel Temperature Sensor Low Error............................................ 582 CA271 - IMV/PCV1 Short Error......................................................... 583 CA272 - IMV/PCV1 Open Error.......................................................... 584 CA273 - PCV2 Short Error............................................................. 585 CA274 - PCV2 Open Error.............................................................. 586 CA322 - Injector #1 Open/short Error................................................. 588 CA323 - Injector #5 Open/short Error................................................. 590 CA324 - Injector #3 Open/short Error................................................. 592 CA325 - Injector #6 Open/short Error................................................. 594 CA331 - Injector #2 Open/short Error................................................. 596 CA332 - Injector #4 Open/short Error................................................. 598 CA342 - Calibration Code Incompatibility............................................. 600 CA351 - Injectors Drive Circuit Error................................................ 602 CA352 - Sensor Supply 1 Volt Low Error............................................... 604 CA386 - Sensor Supply 1 Volt High Error.............................................. 606 CA441 - Battery Voltage Low Error.................................................... 608 CA442 - Battery Voltage High Error................................................... 610 CA449 - Rail Pressure Very High Error................................................ 612 CA451 - Rail Pressure Sensor High Error.............................................. 616 CA452 - Rail Pressure Sensor Low Error............................................... 618 CA553 - Rail Pressure High Error..................................................... 620 CA554 - Rail Pressure Sensor In Range Error.......................................... 621 CA559 - Rail Pressure Low Error...................................................... 622 CA689 - Engine Ne Speed Sensor Error................................................. 626 CA731 - Engine Bkup Speed Sensor Phase Error......................................... 628 CA757 - All Persistent Data Lost Error............................................... 630 CA778 - Engine Bkup Speed Sensor Error............................................... 632 CA1228 - EGR Valve Servo Error 1..................................................... 634 CA1625 - EGR Valve Servo Error 2..................................................... 635 CA1633 - KOMNET Datalink Timeout Error............................................... 636 CA2185 - Throttle Sensor Supply Volt High Error...................................... 638 CA2186 - Throttle Sensor Supply Volt Low Error....................................... 640 CA2249 - Rail Pressure Very Low Error................................................ 641 CA2272 - EGR Valve Lift Sensor Low Error............................................. 644 CA2351 - EGR Valve Solenoid Operation Short Circuit.................................. 646 CA2555 - Grid Htr Relay Volt High Error.............................................. 650 CA2556 - Grid Htr Relay Volt Low Error............................................... 652 D110KB - Battery Relay Drive Short Circuit........................................... 654 D19JKZ - Personal Code Relay Abnormality............................................. 656 D862KA - GPS Antenna Discon.......................................................... 658 DA22KK - Pump Solenoid Power Low Error............................................... 660 DA25KP - 5 V Sensor Power Supply Output 1 Abnormality................................ 662 DA29KQ - Model Selection Abnormality................................................. 666 DA2RMC - CAN Discon (Pump Con Detected).............................................. 668 DAF8KB - Short circuit in camera power supply........................................ 670 DAFGMC - GPS Module Error............................................................ 672 DAFRMC - CAN Discon (Monitor Detected)............................................... 674 DGH2KB - Hyd Oil Sensor Short........................................................ 676 DHPAMA - F Pump Pressure Sensor Abnormality.......................................... 678 DHPBMA - R Pump Pressure Sensor Abnormality.......................................... 681 DHS3MA - Arm Curl In PPC Sensor Abnormality.......................................... 684 DHS4MA - Bucket Curl PPC Pressure Sensor Abnormality................................. 686 DHX1MA - Overload Sensor Abnormality (Analog)........................................ 688 DW43KA - Travel Speed Solenoid Disconnection......................................... 690 DW43KB - Travel Speed Solenoid Short Circuit......................................... 692 DW45KA - Swing Brake Solenoid Disconnection.......................................... 694 DW45KB - Swing Brake Solenoid Short Circuit.......................................... 698 DW91KA - Travel Junction Solenoid Disconnection...................................... 700 DW91KB - Travel Junction Solenoid Short Circuit...................................... 702 DWA2KA - Attachment Sol Open Circuit................................................. 704 DWA2KB - Attachment Sol Short Circuit................................................ 706 DWJ0KA - Merge-divider Solenoid Disconnection........................................ 708 DWJ0KB - Merge-divider Solenoid Short Circuit........................................ 710 DWK0KA - 2-stage Relief Solenoid Disconnection....................................... 712 DWK0KB - 2-stage Relief Solenoid Short Circuit....................................... 714 DXA0KA - PC-EPC Solenoid Disconnection............................................... 716 DXA0KB - PC-EPC Solenoid Short Circuit............................................... 718 DXE0KA - LS-EPC Solenoid Disconnection............................................... 720 DXE0KB - LS-EPC Solenoid Short Circuit............................................... 722 DXE4KA - Service Current EPC Disconnection........................................... 724 DXE4KB - Service Current EPC Short Circuit........................................... 725 DY20KA - Wiper Working Abnormality................................................... 726 DY20MA - Wiper Parking Abnormality................................................... 728 DY2CKA - Washer Drive Open Circuit................................................... 730 DY2CKB - Washer Drive Short Circuit.................................................. 732 DY2DKB - Wiper Drive (Fwd) Short Circuit............................................. 734 DY2EKB - Wiper Drive (Rev) Short Circuit............................................. 736 E-MODE (ELECTRICAL SYSTEM)............................................................... 738 Before Carrying Out Troubleshooting Of Electrical System............................. 738 Information Contained In Troubleshooting Table....................................... 740 E-1 Engine Does Not Start............................................................ 742 E-2 Auto-decelerator Does Not Operate................................................ 746 E-3 Automatic Warming-up System Does Not Operate..................................... 748 E-4 Preheater Does Not Operate....................................................... 750 E-5 All Work Equipment, Swing, And Travel Mechanism Do Not Move...................... 752 E-6 Power Maximizing Function Does Not Operate....................................... 754 E-7 Machine Monitor Does Not Display At All.......................................... 756 E-8 Machine Monitor Does Not Display Some Items...................................... 758 E-9 Contents Of Display By Machine Monitor Are Different From Applicable Machine..... 758 E-10 Fuel Level Monitor Was Lighted In Red While Engine Running...................... 759 E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally..................... 760 E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally...................... 762 E-13 Fuel Level Gauge Does Not Indicate Normally..................................... 763 E-14 Swing Lock Monitor Does Not Indicate Normally................................... 764 E-15 When Monitor Switch Is Operated, Monitor Displays Nothing....................... 766 E-16 Windshield Wiper And Window Washer Do Not Operate............................... 768 E-17 Machine Push-up Function Does Not Operate Normally.............................. 772 E-18 Monitoring Function Fails To Display “Boom Raise” Normally...................... 774 E-19 Monitoring Function Fails To Display “Boom Lower” Normally...................... 776 E-20 Monitoring Function Fails To Display “Arm In” Normally.......................... 778 E-21 Monitoring Function Fails To Display “Arm OUT” Normally......................... 780 E-22 Monitoring Function Fails To Display “Bucket CURL” Normally..................... 782 E-23 Monitoring Function Fails To Display “Bucket DUMP” Normally..................... 784 E-24 Monitoring Function Fails To Display “Swing” Normally........................... 786 E-25 Monitoring Function Fails To Display “Travel” Normally.......................... 788 E-26 Monitoring Function Fails To Display “Travel Differential Pressure” Normally.... 790 E-27 Monitoring Function Fails To Display “Service” Normally......................... 792 E-28 KOMTRAX System Does Not Operate Normally........................................ 794 E-29 Air Conditioner Does Not Operate................................................ 796 E-30 Travel Alarm Does Not Sound Or Does Not Stop Sounding........................... 798 E-31 Horn Does Not Sound............................................................. 800 H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)................................................ 802 System Chart For Hydraulic And Mechanical System..................................... 802 Information Contained In Troubleshooting Table....................................... 804 H-1 All Work Equipment Lack Power, Or Travel And Swing Speeds Are Slow............... 806 H-2 Engine Speed Sharply Drops Or Engine Stalls...................................... 808 H-3 No Work Equipment, Swing Or Travel Move.......................................... 809 H-4 Abnormal Noise Is Heard From Around Hydraulic Pump............................... 809 H-5 Auto-decelerator Does Not Work................................................... 810 H-6 Fine Control Mode Does Not Function Or Responds Slow............................. 810 H-7 Boom Moves Slowly Or Lacks Power................................................. 811 H-8 Arm Moves Slowly Or Lacks Power.................................................. 812 H-9 Bucket Moves Slowly Or Lacks Power............................................... 813 H-10 Work Equipment Does Not Move In Individual Operation............................ 813 H-11 Work Equipment Has A Bit Too Fast Hydraulic Drift............................... 814 H-12 Work Equipment Has Long Time Lag................................................ 816 H-13 Other Work Equipment Moves When Relieving Single Circuit........................ 816 H-14 Power Max. Switch Does Not Operate.............................................. 817 H-15 Machine Push-up Function Does Not Operate....................................... 817 H-16 In Compound Operation Of Work Equipment, Speed Of Part Loaded More Is Low....... 818 H-17 In Swing + Boom Raise Operation, Boom Moves Slowly.............................. 818 H-18 In Swing + Travel Operation, Travel Speed Drops Sharply......................... 818 H-19 Machine Swerves In Travel....................................................... 819 H-20 Machine Travels Slowly.......................................................... 820 H-21 Machine Cannot Be Easily Steered Or Lacks Power................................. 821 H-22 Travel Speed Does Not Shift, Or It Is Too Slow Or Fast.......................... 822 H-23 Travel System Does Not Turn (On One Side Only).................................. 823 H-24 Machine Does Not Swing.......................................................... 824 H-25 Swing Acceleration Is Poor, Or Swing Speed Is Slow.............................. 826 H-26 Excessive Overrun When Stopping Swing........................................... 828 H-27 There Is Big Shock When Stopping Swing.......................................... 829 H-28 Large Sound Is Made When Upper Structure Stops Swinging......................... 829 H-29 Swing Hydraulic Drift Is Too Big................................................ 830 H-30 Attachment Circuit Is Not Changed............................................... 831 H-31 Oil Flow In Attachment Circuit Cannot Be Controlled............................. 832 50 DISASSEMBLY AND ASSEMBLY.................................................................. 833 HOW TO READ THIS MANUAL.................................................................. 837 SPECIAL TOOLS LIST....................................................................... 840 SKETCHES OF SPECIAL TOOLS................................................................ 844 CONNECTOR REPAIR PROCEDURES.............................................................. 849 Contact Terminal Removal (HD30 Type)................................................. 849 Striping Insulation.................................................................. 850 Crimping Contact Terminal (HD30 Type)................................................ 851 Insertion Of Contact Terminal (HD30 Type)............................................ 852 Contact Terminal Removal (DT Type)................................................... 853 Striping Insulation.................................................................. 854 Crimping Contact Terminal (DT Type).................................................. 855 Insertion Of Contact Terminal (DT Type).............................................. 856 ENGINE COMPONENTS........................................................................ 857 Fuel Supply Pump..................................................................... 857 Removal.......................................................................... 857 Installation..................................................................... 861 Fuel Injector........................................................................ 863 Removal.......................................................................... 863 Installation..................................................................... 867 Engine Front Seal.................................................................... 871 Removal.......................................................................... 871 Installation..................................................................... 873 Engine Rear Seal..................................................................... 874 Removal.......................................................................... 874 Installation..................................................................... 876 Cylinder Head........................................................................ 879 Removal.......................................................................... 879 Installation..................................................................... 888 Oil Pan Gasket....................................................................... 892 RADIATOR................................................................................. 893 Removal.............................................................................. 893 Installation......................................................................... 894 HYDRAULIC OIL COOLER..................................................................... 895 Removal.............................................................................. 895 Installation......................................................................... 896 AFTERCOOLER.............................................................................. 897 Removal.............................................................................. 897 Installation......................................................................... 898 ENGINE AND HYDRAULIC OIL PUMP............................................................ 899 Removal.............................................................................. 899 Installation......................................................................... 908 DRIVE ASSEMBLY........................................................................... 909 Removal.............................................................................. 909 Installation......................................................................... 909 Disassembly.......................................................................... 910 Assembly............................................................................. 915 SWING MOTOR AND SWING MACHINERY.......................................................... 921 Removal.............................................................................. 921 Installation......................................................................... 922 Disassembly.......................................................................... 923 Assembly............................................................................. 927 SWING CIRCLE............................................................................. 933 Removal.............................................................................. 933 Installation......................................................................... 933 CARRIER ROLLER........................................................................... 934 Assembly............................................................................. 934 TRACK ROLLER............................................................................. 936 Assembly............................................................................. 936 IDLER.................................................................................... 937 Disassembly.......................................................................... 937 ASSEMBLY............................................................................. 938 RECOIL SPRING............................................................................ 941 Disassembly.......................................................................... 941 Assembly............................................................................. 942 SPROCKET................................................................................. 944 Removal.............................................................................. 944 Installation......................................................................... 944 TRACK SHOE............................................................................... 945 Expansion of Track Shoe.............................................................. 945 Installation of Track Shoe........................................................... 946 REVOLVING FRAME.......................................................................... 947 Removal.............................................................................. 947 Installation......................................................................... 948 COUNTERWEIGHT............................................................................ 950 Removal.............................................................................. 950 Installation......................................................................... 951 COUNTERWEIGHT REMOVER.................................................................... 952 Removing............................................................................. 953 Installing........................................................................... 959 CENTER SWIVEL JOINT...................................................................... 961 Removal.............................................................................. 961 Installation......................................................................... 962 Disassembly.......................................................................... 963 Assembly............................................................................. 964 HYDRAULIC TANK........................................................................... 965 Removal.............................................................................. 965 Installation......................................................................... 966 CONTROL VALVE............................................................................ 967 Removal.............................................................................. 967 Installation......................................................................... 970 Disassembly.......................................................................... 971 Assembly............................................................................. 973 HYDRAULIC PUMP........................................................................... 976 Removal.............................................................................. 976 Installation......................................................................... 978 HYDRAULIC PUMP INPUT SHAFT OIL SEAL...................................................... 979 Removal.............................................................................. 979 Installation......................................................................... 979 WORK EQUIPMENT PPC VALVE................................................................. 980 Disassembly.......................................................................... 980 Assembly............................................................................. 980 TRAVEL PPC VALVE......................................................................... 982 Disassembly.......................................................................... 982 Assembly............................................................................. 983 HYDRAULIC CYLINDER....................................................................... 985 Disassembly.......................................................................... 985 Assembly............................................................................. 988 WORK EQUIPMENT........................................................................... 991 Removal.............................................................................. 991 Installation......................................................................... 993 CAB...................................................................................... 994 Removal.............................................................................. 994 Installation......................................................................... 997 Cab Glass (Stuck Glass).............................................................. 998 Removal.......................................................................... 999 Installation.....................................................................1000 Front Window.........................................................................1009 Removal..........................................................................1009 Installation.....................................................................1011 Floor Frame..........................................................................1017 Removal..........................................................................1017 Installation.....................................................................1021 ELECTRICAL SYSTEMS.......................................................................1022 Air Conditioner Unit.................................................................1022 Removal..........................................................................1022 Installation.....................................................................1026 KOMTRAX Communication Modem..........................................................1027 Removal..........................................................................1027 Installation.....................................................................1027 Monitor..............................................................................1028 Removal..........................................................................1028 Installation.....................................................................1029 Pump Controller......................................................................1030 Removal..........................................................................1030 Installation.....................................................................1030 Engine Controller....................................................................1033 Removal..........................................................................1033 Installation.....................................................................1034 60 AIR CONDITIONER...........................................................................1035 STRUCTURE AND FUNCTION...................................................................1038 Air Conditioner Component............................................................1038 Configuration and Function of Refrigerating cycle....................................1040 Outline of Refrigerating Cycle.......................................................1041 Air Conditioner Unit.................................................................1044 Functions of Major Components in the Air Conditioner Unit............................1046 Control Plate........................................................................1048 Compressor...........................................................................1051 Condenser and Receiver Drier.........................................................1052 TESTING AND ADJUSTING....................................................................1053 Caution About Refrigerant............................................................1053 Troubleshooting Procedure............................................................1054 Block Diagram........................................................................1055 Circuit Diagram and Arrangement of Connector Pins....................................1056 Detail of Air Conditioner Unit.......................................................1058 Part and Connector Locations.........................................................1060 Testing Air Leakage (Ducts)..........................................................1064 Testing with Self-diagnosis Function.................................................1066 Testing Temperature Control..........................................................1069 Testing Vent (Mode) Changeover.......................................................1072 Testing Recirc/Fresh Changeover......................................................1076 Testing Inner Sensor.................................................................1078 Testing Evaporator Temperature Sensor................................................1079 Testing Sunlight Sensor..............................................................1081 Testing (Dual) Pressure Switch for Refrigerant.......................................1082 Testing Relays.......................................................................1084 TROUBLESHOOTING..........................................................................1086 Troubleshooting Chart 1..............................................................1086 Troubleshooting Chart 2..............................................................1087 Troubleshooting for Electrical System (E mode).......................................1090 E-1 Power Supply System (Air Conditioner does not Operate).......................1091 E-2 Compressor System (Air is Not Cooled)........................................1095 E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)...............1098 E-4 Temperature Cannot be Controlled.............................................1102 E-5 Vent (Mode) Cannot be Changed Over...........................................1105 E-6 Recirc/Fresh Air Cannot be Changed Over......................................1108 Troubleshooting With Gauge Pressure..................................................1111 Connection of Service Tool...........................................................1114 Precautions for connecting air conditioner piping....................................1116 Handling of Compressor Oil...........................................................1117 Control of Compressor Oil........................................................1117 Adding of Compressor Oil.........................................................1117 Compressor Replacement...........................................................1118 Applying Compressor Oil for O-ring...............................................1118 Desiccant Replacement Procedure......................................................1119 90 OTHERS....................................................................................1121 Hydraulic circuit diagram................................................................1123 Electrical circuit diagram (1/5).........................................................1124 Electrical circuit diagram (2/5).........................................................1125 Electrical circuit diagram (3/5).........................................................1126 Electrical circuit diagram (4/5).........................................................1127 Electrical circuit diagram (5/5).........................................................1128 Connector list and stereogram............................................................1129
KOMATSU PC450LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:
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