Komatsu PW400MH-6 Material Handler Shop Manual CEBM005600 PDF

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Komatsu PW400MH-6 Material Handler Shop Manual CEBM005600 – PDF DOWNLOAD

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Komatsu PW400MH-6 Material Handler Shop Manual CEBM005600 – PDF DOWNLOAD

Language : English
Pages : 662
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PW400MH-6 Material Handler Shop Manual CEBM005600 – PDF DOWNLOAD

• SERIAL NUMBERS   PW400MH-6 A84210 AND UP

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 5
SAFETY NOTICE 5
IMPORTANT SAFETY NOTICE 5
GENERAL PRECAUTIONS 5
PREPARATIONS FOR WORK 5
PRECAUTIONS DURING WORK 5
FOREWORD 7
GENERAL 7
HOW TO READ THE SHOP MANUAL 8
VOLUMES 8
DISTRIBUTION AND UPDATING 8
FILING METHOD 8
REVISED EDITION MARK 8
REVISIONS 8
SYMBOLS 8
HOISTING INSTRUCTIONS 9
HOISTING 9
WIRE ROPES 9
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 12
TIGHTENING TORQUE OF HOSE NUTS 13
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 13
TIGHTENING TORQUE FOR FLARED NUTS 13
ALTERNATIVE FASTENERS 14
BOLT IDENTIFICATION CHART 14
GRADE 5 AND 8 NONPHOSPHATE COATED HARDWARE 15
GRADE 8 PHOSPHATE COATED HARDWARE 16
STANDARD METRIC FASTENERS 16
HYDRAULIC TUBES AND FITTINGS 17
HOSE CLAMPS 17
SPLIT FLANGE CONNECTIONS 17
ELECTRIC WIRE CODE 18
CLASSIFICATION BY THICKNESS 18
CLASSIFICATION BY COLOR AND CODE 18
CONVERSION TABLES 19
METHOD OF USING THE CONVERSION TABLE 19
01 GENERAL 25
SPECIFICATIONS AND DRAWING 27
SPECIFICATIONS 28
LIFTING PERFORMANCE 29
LIFTING CAPACITY 30
TRANSPORTATION 31
MAIN CARRIER TRANSPORTATION DATA 32
FUEL COOLANT AND LUBRICANTS 33
ENGINE OIL SPECIFICATIONS 34
NORMAL OPERATION 34
ARCTIC OPERATION 34
FINAL DRIVE OIL SPECIFICATIONS 35
DIESEL FUEL SPECIFICATIONS 35
COOLANT SPECIFICATIONS 36
10 STRUCTURE AND FUNCTION 43
ENGINE COMPONENTS 45
TURBO INTAKE PIPING AND ENGINE MOUNTS 45
DRIVE PLATES AND ENGINE MOUNTS 46
RADIATOR AND OIL COOLER 47
POWER TRAIN 48
DRIVE SYSTEM 49
FINAL DRIVE 49
WHEEL FRAME 49
TRAVEL MOTOR 49
TRAVEL CONTROL SYSTEM 49
STRAIGHT-TRAVEL SYSTEM 49
TRAVEL JUNCTION VALVE 49
SWING CIRCLE 50
SWING MACHINERY 51
HYDRAULIC PIPING DRAWING 52
HYDRULIC PIPING SCHEMATIC 53
HYDRAULIC TANK AND FILTER 54
HYDRULIC PUMP 55
MAIN PUMP 56
TVC AND LS VALVE 61
CONTROL VALVE 74
MAIN STRUCTURE OF 9 SPOOL VALVE (1/4) 75
MAIN STRUCTURE OF 9 SPOOL VALVE (2/4) 76
MAIN STRUCTURE OF 9 SPOOL VALVE (3/4) 77
MAIN STRUCTURE OF 9 SPOOL VALVE (4/4) 78
SELF REDUCING PRESSURE VALVE 80
STRUCTURE 80
SUCTION SAFETY VALVE 85
FOR SERVICE VALVE 85
CLSS 86
CLSS HYDRAULICS 89
SYSTEM DIAGRAM 90
WHEN UNLOAD VALVE IS ACTUATED 91
RELIEF VALVE 92
CUT-OFF CONTROL ACTUATED 92
CUT-OFF CANCELED 92
INTRODUCTION OF LS PRESSURE 93
LS BYPASS VALVE 94
PRESSURE COMPENSATION VALVE 95
SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE 98
VARIABLE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE 100
BOOM REGENERATION CIRCUIT 101
ARM REGENERATION CIRCUIT 103
MERGE FLOW DIVIDER VALVE 104
LS SELECT VALVE 106
2-STAGE SAFETY VALVE (INSTALLED TO BOOM CYLINDER HEAD) 107
SWING SYSTEM 108
CENTER SWIVEL JOINT 108
COUNTERBALANCE VALVE 108
SAFETY VALVE 108
SWING MOTOR 109
PW400MH-6 APPLICATION 109
SUCTION-SAFETY VALVE 111
PARKING BRAKE 112
VALVE CONTROL 113
PPC VALVE 114
SERVICE PPC VALVE 114
PPC SAFETY LOCK VALVE 114
TRAVEL PPC VALVE 114
BOOM HOLDING VALVE 114
WORK EQUIPMENT 114
AUTO DECELERATION SYSTEM 114
WORK EQUIPMENT PPC VALVE 115
PPC ACCUMULATOR 117
PPC SHUTTLE VALVE VIEW 118
PPC SHUTTLE VALVE PORT LOCATIONS 119
LS-EPC VALVE 121
SOLENOID VALVE 124
AIR CONDITIONER 126
AIR CONDITIONER PIPING 126
ACTUAL ELECTRICAL WIRING DIAGRAM 127
ACTUAL ELECTRICAL WIRING DIAGRAM (2/2) 130
ENGINE CONTROL 131
COMPONENTS OF SYSTEM 133
ELECTRONIC CONTROL SYSTEM 137
CONTROL FUNCTION 137
PUMP AND ENGINE MUTUAL CONTROL SYSTEM 139
CONTROL METHOD IN EACH MODE 140
PUMP AND VALVE CONTROL FUNCTION 141
AUTOMATIC WARM-UP AND ENGINE OVERHEAT PROTECTION 143
SWING CONTROL SYSTEM 145
SWING LOCK AND SWING HOLDING BRAKE 146
COMPONENTS OF SYSTEM 147
MACHINE MONITOR SYSTEM 150
MONITOR PANEL FRONT AND BACK VIEW 151
MONITOR DISPLAY 152
CONTENT OF DISPLAY 153
OIL MAINTENANCE FUNCTION 154
MODE SELECTION SWITCHES 155
SENSORS 156
COOLANT LEVEL SENSOR 156
COOLANT TEMPERATURE SENSOR 157
OIL PRESSURE AND LEVEL SENSOR 158
FUEL LEVEL SENSOR 159
20 TESTING, ADJUSTING AND TROUBLESHOOTING 161
STANDARD VALUE TABLE FOR ENGINE 162
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 163
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 167
SERVICE TOOLS TABLE 172
ENGINE COMPONENTS 173
ADJUSTING ENGINE STOP LINKAGE 173
ADJUSTING ENGINE STOP SOLONOID 173
MEASURING AND ADJUSTING VALVE CLEARANCE 173
MEASURING BLOW-BY PRESSURE 173
MEASURING COMPRESSION PRESSURE 173
MEASURING COOLANT TEMPERATURE 173
MEASURING ENGINE LUBRICATING PRESSURE 173
MEASURING ENGINE SPEEDS 173
MEASURING ENGINE EXHAUST SMOKE 173
MEASURING EXHAUST GAS TEMPERATURE 173
MEASURING FUEL FILTER INLET RESTRICTION 173
TESTING AND ADJUSTING BELT TENSIONS 173
TESTING AND ADJUSTING FUEL INJECTION TIMING 173
GOVERNOR MOTOR LEVER STROKE 174
WORK AND SWING EQUIPMENT 175
TVC VALVE OUTPUT PRESSURE 178
LS VALVE OUTPUT AND DIFFERENTIAL PRESSURE 180
CONTROL CIRCUIT OIL PRESSURE 183
SOLENOID VALVE OUTPUT PRESSURE 184
PPC VALVE OUTPUT PRESSURE AND SHUTTLE VALVE 187
WORK EQUIPMENT, SWING PPC VALVE 189
TRAVEL DEVIATION 190
LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 191
MEASURING OIL LEAKAGE 193
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 195
TESTING CLEARANCE OF SWING CIRCLE BEARING 196
BLEEDING AIR 197
TROUBLESHOOTING – GENERAL 201
POINTS TO REMEMBER WHEN TROUBLESHOOTING 203
SEQUENCE OF EVENTS IN TROUBLESHOOTING 205
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 206
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 206
HANDLING CONTROL BOX 211
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 212
CHECKS BEFORE TROUBLESHOOTING 214
JUDGEMENT OF POWER TRAIN 215
PRECAUTIONS WHEN TROUBLESHOOTING 216
SAFETY 216
METHODS FOR TROUBLESHOOTING 216
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING 218
PREVENTING RECURRENCE OF TROUBLE 219
HYDRAULIC EQUIPMENT 219
OIL CHECKS 219
CLEANING FRAGMENTS OFF DAMAGED PARTS 219
METHOD OF USING TROUBLESHOOTING CHARTS 220
CATEGORY OF TROUBLESHOOTING CODE NUMBER 220
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE 220
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 222
METHOD OF USING ENGINE RELATED CHARTS 224
TROUBLESHOOTING ELECTRICAL CONNECTORS 229
CONNECTOR TYPES AND MOUNTING LOCATIONS 230
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 233
CONTROL MECHANISM FOR ELECTRICAL SYSTEM 243
MACHINE CONTROL FUNCTIONS 243
DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL 244
DISPLAY ON MACHINE MONITOR 244
RECORDING SERVICE CODES AND USER CODE 244
MACHINE DATA MONITORING FUNCTION 245
METHOD OF DISPLAYING MONITORING CODE 246
TABLE OF MACHINE MONITORING CODES 247
BIT PATTERN CHART 248
GOVERNOR MOTOR ADJUSTMENT MODE 250
TIME ADJUSTMENT MODE 250
WORKING MODE DEFAULT SETTING MODE 251
METHOD OF USING JUDGEMENT TABLE 252
WHEN USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYS-TEM] AND ENGINE RE 252
EXAMPLE TABLE 252
USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYSTEM] AND HYDRAULIC RELAT 254
EXAMPLE TABLE 254
METHOD OF USING TROUBLESHOOTING CHARTS 256
CATEGORY OF TROUBLESHOOTING CODE NUMBER 256
GENERAL PRECAUTIONS 256
DETAILS OF TROUBLESHOOTING AND PROCEDURE 259
PROCEDURE FOR CHECKING MONITOR PANEL OUTPUT SIGNAL 261
CHECKING INPUT SIGNAL OF GOVERNOR, PUMP CONTROLLER 262
SERVICE CODE TABLE 264
TROUBLESHOOTING COMMUNICATION SYSTEM (N-MODE) 265
N-1 [E218] COMMUNICATION ABNORMALITY 266
TROUBLESHOTING GOVERNOR PUMP CONTROLLER AND SYSTEM (E-MODE) 269
POINTS TO REMEMBER WHEN TROUBLESHOOTING GOVERNOR, PUMP CONTROLLER SYSTEM 270
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE, (CONTROLLER LED IS OFF) 275
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT (VALUE IS DISPLAYED) 276
E-3 [E317] ABNORMALITY, DISCONNECTION IN MOTOR DRIVE SYSTEM IS DISPLAYED 277
E-4 [E318] ABNORMALITY, SHORT CIRCUIT IN MOTOR DRIVE SYSTEM IS DISPLAYED 278
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED 279
E-6 [E315] SHORT CIRCUIT IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED 280
E-7 [E316] ABNORMALITY, STEP OUT IN MOTOR DISPLAYED 282
E-8 ENGINE DOES NOT START 283
(A) IDLE SPEED IS IRRERGULAR 285
(B) ENGINE SPEED HUNTING 286
E-10 LACK OF OUTPUT, ENGINE HIGH IDLE SPEED IS LOW 287
E-11 ENGINE DOES NOT STOP 288
E-12 FAULTY OPERATION OF BATTERY RELAY SYSTEM, (ENGINE DOES NOT STOP) 289
TROUBLESHOOTING ENGINE SYSTEM (S-MODE) 292
METHOD OF USING ENGINE CHARTS 293
S-1 ENGINE STARTING PERFORMANCE IS POOR 298
S-2 ENGINE DOES NOT START 299
S-3 ENGINE STARTS ROUGH 302
S-4 ENGINE QUITS DURING OPERATION 303
S-5 ENGINE SPEED IS HUNTING 304
S-6 ENGINE POWER OUTPUT IS POOR 305
S-7 EXHAUST GAS IS BLACK (POOR COMBUSTION) 306
S-8 ENGINE OIL CONSUMPTION IS EXCESSIVE (EXHAUST GAS IS BLUE) 307
S-9 ENGINE OIL BECOMES CONTAMINATED QUICKLY 308
S-10 EXCESS FUEL CONSUMPTION 309
S-11 OIL IN COOLANT, COOLANT BLOWS OUT OF SYSTEM DURING OPERATION 310
S-12 OIL PRESSURE LIGHT STAYS ON (OIL PRESSURE LOW) 311
S-13 OIL LEVEL RISES OR OIL LOOKS ABNORMAL 312
S-14 HIGH COOLANT TEMPERATURES (OVERHEATING) 313
S-15 ABNORMAL NOISES COMING FROM ENGINE COMPARTMENT 314
S-16 EXCESSIVE ENGINE VIBRATION 315
TROUBLESHOOTING GOVERNOR PUMP AND CONTROL SYSTEM (C-MODE) 317
IMPORTANT POINTS WHEN TROUBLESHOOTING CONTROLLER SYSTEM 318
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 319
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS 323
ELECTRIC CIRCUIT DIAGRAM FOR (C MODE) 324
C1 ABNORMALITY IN CONTROLLER POWER SOURCE, LED IS OFF 326
C-2 [232] SHORT CIRCUIT IN FRONT PUMP TVC SOLONOID IS DISPLAYED 327
C-3 [E233] DISCONECTION IN FRONT PUMP TVC SOLENOID IS DISPLAYED 328
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID IS DISPLAYED 329
C-5 [E237] DISCONECT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED 330
C-6 [E207] SHORT CIRCUIT IN LS SELECT SOLENOID SYSTEM IS DISPLAYED 331
BLANK FAULT CODES 332
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED 333
C-9 [E213] DISCONECT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED 334
C-10 [E204] SHORT CIRCUIT IN PUMP MERGE DIVIDER SOLENOID IS DISPLAYED 335
C-11 [E214] DISCONECT IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED 336
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED 337
C-16 RELATED ELECTRIC CIRCUIT DIAGRAM 338
C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED 339
C-18 [E224] DISCONECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED 340
C-19 [E224] ABNORMALITY IN FRONT FUMP PRESSURE SENSOR SYSTEM IS DISPLAYED 341
C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED 342
C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED 343
C-22 [E227] ABNORMALITY IN ENGINE SPEED SYSTEM IS DISPLAYED 344
TROUBLESHOOTING GOVERNOR PUMP CONTROLLER INPUT SIGNAL (F-MODE) 346
ELECTRIC CIRCUIT DIAGRAM FOR (F MODE) 348
F1 BIT PATTERN 20-[1] SWING OIL PRESSURE SWITCH LIGHT INNOPERATIVE 349
F-2 BIT PATTERN 20-[2] NOT USED 350
F-3 BIT PATTERN 20-[3] BOOM LOWER OIL PRESSURE SWITCH LIGHT INNOPERATIVE 351
F-4 BIT PATTERN 20-[4] BOOM RAISE OIL PRESSURE SWITCH LIGHT INNOPERATIVE 352
F-5 BIT PATTERN 20-[5] ARM IN OIL PRESSURE SWITCH LIGHT INNOPERATVE 353
F-6 BIT PATTERN 20-[60] ARM OUT OIL PRESSURE SWITCH LIGHT INNOPERATIVE 354
F-7 BIT PATTERN 12-[1] GRAPPLE OPEN OIL PRESSURE SWITCH LIGHT INNOPERATIVE 355
F-8 BIT PATTERN 12-[2] GRAPPLE CLOSED OIL PRESSURE LIGHT INNOPERATIVE 356
F-9 BIT PATTERN 21-[3] SWING LOCK OIL PRESSURE SWITCH LIGHT INNOPERATIVE 357
F-10 BIT PATTERN 22-[5] MODE CONNECTION LIGHT INNOPERATIVE 358
F-11 BIT PATTERN 22-[6] NOT USED 359
TROUBLESHOOTING MACHINE MECHANICAL SYSTEM (H-MODE) 361
PUMP MERGE DIVIDER LOGIC 362
SOLENOID ACTUATION TABLE 362
TABLE OF FAILURE MODES AND CAUSES 363
H-1 SPEEDS OF WORK EQUIPMENT ARE SLOW OR LACK POWER 365
H-2 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 366
H-3 NO WORK EQUIPMENT OR SWING MOVEMENT 366
H-4 ABNORMAL NOISE GENERATED AROUNG PUMPS 367
BLANK FAULT CODES 368
H-7 BOOM IS SLOW OR LACKS POWER 369
H-8 ARM IS SLOW OR LACKS POWER 370
H-11 EXCESSIVE HYDRAULIC DRIFT 371
1) EXCESSIVE HYDRAULIC DRIFT OF BOOM 371
2) EXCESSIVE HYDRAULIC DRIFT OF ARM 371
H-12 EXCESSIVE TIME LAG (ENGINE AT IDLE) 372
H-13 OTHER EQUIPMENT MOVES WHEN SIGNAL CIRCUIT IS RELIEVED 372
H-25 DOES NOT SWING 373
H-26 SWING ACCELERATION IS POOR OR SLOW 374
H-27 EXCESSIVE OVERRUN WHEN STIPPING SWING MOTION 375
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 376
H-29 ABNORMAL NOISE WHEN STOPPING SWING 376
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING 377
H-31 SWING SPEED FASTER THAN SPECIFIED SWING SPEED 377
TROUBLESHOOTING MACHINE MONITOR SYSTEM (M-MODE) 378
ACTIONS TAKEN BY MONITOR PANEL 380
ELECTRIC CIRCUIT DIAGRAM FOR M MODE 381
M-1 [E101] ABNORMALITY IN DATA OR IN CLOCK IS DISPLAYED 382
M-2 [E103] SHORT CIRCUIT IN BUZZER DISPLAYED 383
M-3 [E104] AIR CLEANER RESTRICTION DETECTION DISPLAYED 384
M-4 [E106] MAJOR DROP IN ENGINE OIL PRESSURE IS DISPLAYED 384
M-5 [E108] 105° ENGINE COOLANT TEMPERATURE IS DISPLAYED 384
M-6 NO DISPLAY IN MONITOR PANEL WHEN IGNITION SWITCH IS IN THE “NO” POSITION 385
M-7 WARNING LIGHTS ON MONITOR REMAIN ILLUMINATED WHILE MACHINE IS RUNNING 387
M-8 MONITOR PANEL DISPLAYS INCORRECT INFORMATION AFTER MACHINE IS RUNNING 387
M-9 WITH IGNITION SWITCH IN “ON” POSITION AND ENGINE OFF MONITOR PANEL DISPLAY FLASHES 388
M-10 PREHEAT INDICATOR REMAINS ON AFTER ENGINE IS RUNNING 391
M-11 WITH ENGINE RUNNING, MONITOR PANEL DISPLAY FLASHES 392
M-12 WITH IGNITION SRITCH IN THE “ON” POSITION, ENGINE SPEED, CAUTION AND EMERGENCY ITEMS FLASH W 394
M-13 WITH ENGINE RUNNING, CAUTION AND EMERGENCY ITEMS FLASH DURING NORMAL OPERATION 396
M-14 WITH IGNITION SWITCH ON, AND ENGINE OFF, CAUTION ITEMS FLASH BUT DO NOT SOUND 399
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR PANEL BUT BUZZER SOUNDS 400
M-16 DISPLAY ON MONITOR PANEL WORKS BUT NIGHT LIGHT ON PANEL DOES NOT ILLUMINATE 401
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE 402
M-18 COOLANT TEMPERATURE GAUGE DOES NOT WORK DURING NORMAL OPERATION 403
M-19 FUEL LEVEL GAUGE STUCK AT “FULL” INDICATION 404
M-20 FUEL LEVEL GAUGE DOES NOT WORK 405
M-12 SWING LOCK ON, BUT MONITOR PANEL DISPLAY DOES NOT WORK 406
M-22 SWING PROLIX SEITCH IS ON, BUT MONITOR PANEL DISPLAY DOES NOT FLASH 407
M-23 HOUR METER DOES NOT WORK WHILE ENGINE IS RUNNING 408
M-24 WITH IGNITION SWITCH IN THE “OFF” POSITION, CLOCK AND HOUR METER ARE NOT DISPLAYED WHEN TIME 408
M-25 FAULTY FUEL LEVER SENSOR SYSTEM 409
M-26 FAULTY COOLANT TEMPERATURE SENSOR SYSTEM 410
M-27 FAULTY OIL LEVEL SENSOR SYSTEM 411
M-28 FAULTY COOLANT LEVEL SENSOR SYSTEM 412
M-29 FAULTY HYDRAULIC OIL LEVEL SENSOR SYSTEM 413
M-30 [E112,113] WIPER OPERATION IS ABNORMAL WITH SWITCH IN THE “OFF” POSITION 414
M-31 WASHER WORKS, BUT WIPER DOES NOT WORK 418
30 DISASSEMBLY AND ASSEMBLY 420
SPECIAL TOOL LIST 424
SKETCHES OF SPECIAL TOOLS 428
ENGINE COMPONENTS 433
ALTERNATOR ASSEMBLY 433
AFTERCOOLER CORE ASSEMBLY 433
CYLINDER HEAD ASSEMBLY 433
CRANKSHAFT DAMPER AND PULLYASSEMBLY 433
ENGINE OIL COOLER ASSEMBLY 433
ENGINE OIL PUMP ASSEMBLY 433
FUEL INJECTION PUMP ASSEMBLY 433
FUEL INJECTOR ASSEMBLY 433
FRONT AND REAR ENGINE OIL SEAL ASSEMBLY 433
GOVERNOR ASSEMBLY 433
STARTER MOTOR ASSEMBLY 433
THERMOSTAT ASSEMBLY 433
TURBORCHARGER ASSEMBLY 433
WATER PUMP ASSEMBLY 433
OIL COOLER 434
REMOVAL 434
INSTALLATION 435
RADIATOR, OIL COOLER AND AC CONDENSER 436
REMOVAL 436
INSTALLATION 439
ENGINE WITH MAIN PUMP 440
REMOVAL 440
INSTALLATION 443
DAMPER 445
REMOVAL 445
INSTALLATION 445
FUEL TANK 446
REMOVAL 446
INSTALLATION 446
CENTER SWIVEL JOINT 447
REMOVAL 447
INSTALLATION 447
DISASSEMBLY 448
ASSEMBLY 448
SWING MOTOR 449
REMOVAL 449
INSTALLATION 449
DISASSEMBLY 450
ASSEMBLY 452
SWING MACHINERY 458
REMOVAL 458
INSTALLATION 458
DISASSEMBLY 459
ASSEMBLY 462
REVOLVING FRAME 467
REMOVAL 467
INSTALLATION 468
SWING CIRCLE 469
REMOVAL 469
INSTALLATION 469
TRAVEL AND CARRIER SYSTEM 470
HYDRAULIC TANK AND PIPING 470
TRAVEL SYSTEM HYDRAULICS 470
TRAVEL MOTOR 470
DRIVE AXLES REDUCTION BOXES 470
STEERING SYSTEM 470
BRAKING SYSTEM 470
OUTRIGGER SYSTEM 470
WORK SYSTEM 471
ARM AND BOOM 471
WORK EQUIPMENT 471
BOOM CYLINDER AND PIPING 471
ARM CYLINDER AND PIPING 471
AUXILLURY PUMP SYSTEM 471
GENERATOR AND ELECTRICAL SYSTEM 471
EQUIPMENT CONTROLS 471
MAIN PUMP 472
REMOVAL 472
INSTALLATION 473
DISASSEMBLY 474
PUMPS, FRONT AND REAR 474
FRONT PUMP TAIR DOWN 474
REAR PUMP TAIR DOWN 479
ASSEMBLY 483
FRONT PUMP 483
MAIN PUMP OIL SEAL 502
REMOVAL 502
INSTALLATION 502
CONTROL VALVE 503
REMOVAL 503
INSTALLATION 505
DISASSEMBLY 506
(1/3) 506
(2/3) 507
(3/3) 508
ASSEMBLY 511
(1/3) 511
(2/3) 512
(3/3) 513
PUMP MERGE DIVIDER VALVE 517
DISASSEMBLY 517
ASSEMBLY 517
PRESSURE COMPENSATION VALVE 518
DISASSEMBLY 518
ASSEMBLY 518
FRONT PUMP SERVO VALVE 519
REMOVAL 519
INSTALLATION 519
REAR PUMP SERVO VALVE 520
REMOVAL 520
INSTALLATION 520
LS-EPC SOLENOID VALVE 521
REMOVAL 521
INSTALLATION 521
SOLENOID VALVE 522
REMOVAL 522
INSTALLATION 522
WORK EQUIPMENT PPC VALVE 523
REMOVAL 523
INSTALLATION 523
DISASSEMBLY 524
ASSEMBLY 524
PPC SHUTTLE VALVE 526
REMOVAL 526
INSTALLATION 527
DISASSEMBLY 527
ASSEMBLY 528
OPERATORS CAB 529
REMOVAL 529
INSTALLATION 530
COUNTERWEIGHT 531
REMOVAL 531
INSTALLATION 531
COMPRESSOR 532
REMOVAL 532
INSTALLATION 532
CONDENSER 533
REMOVAL 533
INSTALLATION 533
RECEIVER DRYER 534
REMOVAL 534
INSTALLATION 534
AIR CONDITIONER UNIT 535
REMOVAL 535
INSTALLATION 536
GOVERNOR, PUMP CONTROLLER 537
REMOVAL 537
INSTALLATION 537
MONITOR PANEL 538
REMOVAL 538
INSTALLATION 538
CONTROL STAND CASE 539
REMOVAL 539
TRAY 539
BOOT 539
UPPER CASE 540
INSTALLATION 540
40 MAINTENANCE STANDARD 542
ENGINE MOUNTS 544
RADIATOR AND OIL COOLER MOUNTINGS (1/2) 545
RADIATOR AND OIL COOLER MOUNTINGS (2/2) 546
SPECIFICATIONS FOR RADIATOR AND OIL COOLER MOUNTINGS 547
SWING MACHINERY 548
SWING CIRCLE 550
HYDRAULIC PUMP 551
CONTROL VALVE 552
SELF REDUCING PRESSURE VALVE 562
SUCTION SAFETY VALVE 563
SWING MOTOR 564
WORK EQUIPMENT • SWING PPC VALVE 565
LS-EPC VALVE 567
SOLENOID VALVE 568
CENTER SWIVEL JOINT 569
90 OTHERS 571
HYDRAULIC PIPING DRAWING 573
HYDRAULIC PIPING SCHEMATIC 575
DETAILS OF TROUBLESHOOTING, AND TROUBLESHOOTING PROCEDURE 585
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART I) 587
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART II) 589
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER AND ENGINE RELATED PARTS 591
ELECTRICAL CIRCUIT DIAGRAM FOR (E) MODE 593
(E-8) ENGINE DOES NOT START 595
(A) IDLE SPEED IS IRREGULAR 597
(B) ENGINE SPEED IS HUNTING 599
(E-10) LACK OF OUTPUT, ENGINE HIGH IDLE SPEED IS LOW 601
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART I) 605
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART II) 607
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART III) 609
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE ( PART IV) 611
(E-11) ENGINE DOES NOT STOP 603
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS 613
ELECTRIC CIRCUIT DIAGRAM FOR (C) MODE 615
C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED 617
C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED 619
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED 621
C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED 623
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED 625
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED 627
C-11 [E214] DISCONNECTION IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED 629
ELECTRIC CIRCUIT DIAGRAM FOR (F) MODE 631
TABLE OF FAILURE MODES AND CAUSES (1/2) 633
TABLE OF FAILURE MODES AND CAUSES (2/2) 635
(H-1) SPEEDS OF ALL WORK EQUIPMENT, SWING, ARE SLOW OR LACK POWER 637
(H-4) ABNORMAL NOISE GENERATED AROUND PUMP 639
(H-7) BOOM IS SLOW OR LACKS POWER 641
(H-26) SWING ACCELERATION IS POOR OR SLOW 645
(H-8) ARM IS SLOW OR LACKS POWER 643
ACTIONS TAKEN BY MONITOR WHEN ABNORMALITY OCCURS ON MACHINE 647
ELECTRICAL CIRCUIT DIAGRAM FOR (M) MODE 649
(M-30) WIPER OPERATION IS ABNORMAL WITH SWITCH NOT BEING USED [Include E112, E113] 651
(M-31) WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED [Include E114] 655
RADIATOR AND OIL COOLER MOUNTINGS (1/2) 657
RADIATOR AND OIL COOLER MOUNTINGS (2/2) 659

DESCRIPTION:

Komatsu PW400MH-6 Material Handler Shop Manual CEBM005600 – PDF DOWNLOAD

• SERIAL NUMBERS   PW400MH-6 A84210 AND UP

GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding
of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand
the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion
of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

G.B  16/12/24