Komatsu PC400-7E0 PC400LC-7E0 PC450-7E0 PC450LC-7E0 Excavator Workshop Repair Service Manual PDF - MKMTSPC400E0PC450LCE0.zip
This is a full factory-level service and repair manual, complete with Electrical Wiring Diagrams, covering the Komatsu Hydraulic Excavator models PC400-7E0, PC400LC-7E0, PC450-7E0 and PC450LC-7E0. It contains every technical detail needed to service, troubleshoot, overhaul and rebuild these machines the way professional technicians do.
Included in the Komatsu Hydraulic Excavator PC400-7E0, PC400LC-7E0, PC450-7E0 and PC450LC-7E0 workshop service repair manual:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,398 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN03578-04 - Hydraulic Excavator PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0 Shop Manual.pdf
TEN00130-10 - Hydraulic Excavator PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0 Operation & Maintenance Manual.pdf
MAIN SECTIONS
SEN03578-04 - Hydraulic Excavator PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0 Shop Manual....2
COVER....2
00 Index and foreword....0
Index....3
Composition of shop manual....4
Table of contents....6
Foreword and general information....15
Safety notice....16
How to read the shop manual....21
Explanation of terms for maintenance standard....23
Handling of electric equipment and hydraulic component....25
Handling of connectors newly used for engines....34
How to read electric wire code....37
Precautions when carrying out operation....40
Method of disassembling and connecting push-pull type coupler....43
Standard tightening torque table....46
Conversion table....50
01 Specification....0
Specification and technical data....57
Specification dimension drawings....58
Specifications....62
Weight table....68
Table of fuel, coolant and lubricants....72
10 Structure, function and maintenance standard....0
Engine and cooling system....75
Engine related parts....76
Radiator, oil cooler and aftercooler....77
Power train....79
Power train....80
Final drive....82
Sprocket....84
Swing machinery....86
Swing circle....88
Undercarriage and frame....91
Track frame and recoil spring....92
Idler....94
Carrier roller....96
Track roller....97
Track shoe....98
Hydraulic system, Part 1....103
Hydraulic equipment layout drawing....104
Hydraulic tank and filter....106
Hydraulic pump....108
Hydraulic system, Part 2....133
Control valve....134
CLSS....158
Functions and operation by valve....162
Merge-divider valve....179
Attachment circuit selector valve....204
Holding valve....206
Hydraulic system, Part 3....213
Valve control....214
PPC valve....216
Solenoid valve....232
PPC accumulator....234
Return oil filter....235
Center swivel joint....236
Travel motor....237
Swing motor....249
Hydraulic cylinder....258
Work equipment....263
Work equipment....264
Dimensions of components....268
Cab and its attachments....273
Air conditioner piping....274
Electrical system....277
Engine control....278
Electronic control system....287
Monitor system....312
Sensor....330
KOMTRAX system....333
20 Standard value table....0
Standard service value table....337
Standard value table for engine related parts....338
Standard value table for chassis related parts (Backhoe specification)....339
Standard value table for chassis related parts (Loading shovel specification)....348
30 Testing and adjusting....0
Testing and adjusting, Part 1....359
Tools for testing, adjusting and troubleshooting....361
Measuring engine speed....365
Measuring air boost pressure....366
Measuring exhaust temperature....367
Measuring exhaust gas color....368
Adjusting valve clearance....369
Measuring compression pressure....371
Measuring blow-by pressure....373
Measuring engine oil pressure....374
Measuring EGR valve and bypass valve drive pressure....375
Handling fuel system parts....376
Releasing residual pressure from fuel system....376
Measuring fuel pressure....377
Handling during cylinder cut-out operation....378
Handling during no injection cranking operation....378
Measuring fuel return rate and leakage....379
Bleeding air from fuel circuit....382
Checking fuel circuit for leakage....384
Checking and adjusting fan belt and alternator belt tension....385
Checking and adjusting air conditioner compressor belt tension....386
Measuring swing circle bearing clearance....387
Checking and adjusting track shoe tension....388
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits....389
Measuring control circuit basic pressure....393
Checking and adjusting pump PC control circuit oil pressure....394
Checking and adjusting pump LS control circuit oil pressure....397
Measuring solenoid valve output pressure....402
Measuring PPC valve output pressure....405
Adjusting play of work equipment and swing PPC valves....406
Inspecting locations of hydraulic drift of work equipment....407
Releasing residual pressure from hydraulic circuit....409
Measuring oil leakage amount....410
Bleeding air from various parts....413
Testing and adjusting, Part 2....417
Special functions of machine monitor....418
Testing and adjusting, Part 3....447
Procedure for turning on KOMTRAX terminal....448
Indication by KOMTRAX terminal lamps....451
Handling voltage circuit of engine controller....454
Preparation work for troubleshooting of electrical system....455
Procedure for testing diodes....460
Pm clinic service....461
Undercarriage troubleshooting report....468
40 Troubleshooting....0
Failure code table and fuse locations....471
Failure codes table....472
Before carrying out troubleshooting when failure code is displayed....476
Information related to troubleshooting....481
Points to remember when troubleshooting....482
Sequence of events in troubleshooting....483
Checks before troubleshooting....484
Classification and troubleshooting steps....485
Information in troubleshooting table....486
Connection table for connector pin numbers....491
T- branch box and T- branch adapter table....527
Troubleshooting by failure code (Display of code), Part 1....531
Failure code [AA10NX] Aircleaner Clogging....534
Failure code [AB00KE] Charge Voltage Low....536
Failure code [B@BAZG] Eng Oil Press. Low....538
Failure code [B@BAZK] Eng. Oil Level Low....540
Failure code [B@BCNS] Eng. Water Overheat....542
Failure code [B@BCZK] Eng. Water Lvl Low....544
Failure code [B@HANS] Hydr. Oil Overheat....546
Failure code [CA111] ECM Critical Internal Failure....548
Failure code [CA115] Eng Ne and Bkup Speed Sens Error....550
Failure code [CA122] Chg Air Press Sensor High Error....551
Failure code [CA123] Chg Air Press Sensor Low Error....553
Failure code [CA131] Throttle Sensor High Error....554
Failure code [CA132] Throttle Sensor Low Error....556
Failure code [CA135] Eng Oil Press Sensor High Error....557
Failure code [CA141] Eng Oil Press Sensor Low Error....559
Failure code [CA144] Coolant Temp Sens High Error....560
Failure code [CA145] Coolant Temp Sens Low Error....562
Failure code [CA153] Chg Air Temp Sensor High Error....564
Failure code [CA154] Chg Air Temp Sensor Low Error....566
Failure code [CA187] Sens Supply 2 Volt Low Error....568
Failure code [CA221] Ambient Press Sens High Error....570
Failure code [CA222] Ambient Press Sens Low Error....572
Failure code [CA227] Sens Supply 2 Volt High Error....573
Failure code [CA234] Eng Overspeed....575
Failure code [CA238] Ne Speed Sens Supply Volt Error....576
Failure code [CA263] Fuel Temp Sensor High Error....578
Failure code [CA265] Fuel Temp Sensor Low Error....580
Failure code [CA271] IMV/PCV1 Short Error....581
Failure code [CA272] IMV/PCV1 Open Error....582
Failure code [CA273] PCV2 Short Error....584
Failure code [CA274] PCV2 Open Error....585
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error....586
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error....588
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error....590
Failure code [CA325] Inj #6 (L/B#6) Open/Short Error....592
Failure code [CA331] Inj #2 (L/B#2) Open/Short Error....594
Failure code [CA332] Inj #4 (L/B#4) Open/Short Error....596
Troubleshooting by failure code (Display of code), Part 2....599
Failure code [CA342] Calibration Code Incompatibility....601
Failure code [CA351] Injectors Drive Circuit Error....602
Failure code [CA352] Sens Supply 1 Volt Low Error....604
Failure code [CA386] Sens Supply 1 Volt High Error....606
Failure code [CA441] Battery Voltage Low Error....608
Failure code [CA442] Battery Voltage High Error....610
Failure code [CA449] Rail Press Very High Error....612
Failure code [CA451] Rail Press Sensor High Error....616
Failure code [CA452] Rail Press Sensor Low Error....618
Failure code [CA553] Rail Press High Error....620
Failure code [CA554] Rail Press Sensor In Range Error....621
Failure code [CA559] Rail Press Low Error....622
Failure code [CA689] Eng Ne Speed Sensor Error....626
Failure code [CA731] Eng Bkup Speed Sens Phase Error....628
Failure code [CA757] All Persistent Data Lost Error....629
Failure code [CA778] Eng Bkup Speed Sensor Error....630
Failure code [CA1228] EGR Valve Servo Error 1....632
Failure code [CA1625] EGR Valve Servo Error 2....633
Failure code [CA1633] KOMNET Datalink Timeout Error....634
Failure code [CA2185] Throt Sens Sup Volt High Error....636
Failure code [CA2186] Throt Sens Sup Volt Low Error....638
Failure code [CA2249] Rail Press Very Low Error....639
Failure code [CA2271] EGR Valve Lift Sens High Error....640
Failure code [CA2272] EGR Valve Lift Sens Low Error....642
Failure code [CA2351] EGR Valve Sol Current High Error....644
Failure code [CA2352] EGR Valve Sol Current Low Error....646
Failure code [CA2555] Grid Htr Relay Volt Low Error....648
Failure code [CA2556] Grid Htr Relay Volt High Error....650
Failure code [D110KB] Battery Relay Drive Short Circuit....652
Failure code [D196KA] Service Return Relay Open Circuit....654
Failure code [D196KB] Service Return Relay Short Circuit....656
Failure code [DA25KP] 5V Sensor 1 Power Abnormality....658
Failure code [DA80MA] Auto. Lub. Abnormal....660
Troubleshooting by failure code (Display of code), Part 3....663
Failure code [DA2RMC] Pump Comm. Abnormality....666
Failure code [DA2SKQ] Model Selection Abnormality....668
Failure code [DAFRMC] Monitor Comm. Abnormality....670
Failure code [DGH2KB] Hydr Oil Sensor Short Circuit....672
Failure code [DHPAMA] F Pump Press Sensor Abnormality....674
Failure code [DHPBMA] R Pump Press Sensor Abnormality....676
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality....678
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality....680
Failure code [DW43KA] Travel Speed Sol. Open Circuit....682
Failure code [DW43KB] Travel Speed Sol. Short Circuit....684
Failure code [DW45KA] Swing Brake Sol. Open Circuit....686
Failure code [DW45KB] Swing Brake Sol. Short Circuit....690
Failure code [DW91KA] Travel Junction Sol. Open Circuit....692
Failure code [DW91KB] Travel Junction Sol. Short Circuit....694
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit....696
Failure code [DWJ0KB] Merge-Divider Sol. Short Circuit....698
Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit....700
Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit....702
Failure code [DXA0KA] PC-EPC Sol. Open Circuit....704
Failure code [DXA0KB] PC-EPC Sol. Short Circuit....706
Failure code [DXE0KA] LS-EPC Sol. Open Circuit....708
Failure code [DXE0KB] LS-EPC Sol. Short Circuit....710
Failure code [DXE4KA] Service Current EPC Open Circuit....712
Failure code [DXE4KB] Service Current EPC Short Circuit....713
Failure code [DY20KA] Wiper Working Abnormality....714
Failure code [DY20MA] Wiper Parking Abnormality....716
Failure code [DY2CKB] Washer Drive Short Circuit....718
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit....720
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit....722
Troubleshooting of electrical system (E-mode)....725
Before carrying out troubleshooting of electrical system....728
Information contained in troubleshooting table....730
E-1 Engine does not start....731
E-2 Auto-decelerator does not operate....734
E-3 Automatic warming-up does not operate....736
E-4 Preheater does not operate....738
E-5 All work equipment, swing, and travel mechanism do not move....740
E-6 Power maximizing function does not operate....742
E-7 Machine monitor does not display at all....744
E-8 Machine monitor does not display some items....746
E-9 Contents of display by machine monitor are different from applicable machine....746
E-10 Fuel level monitor was lighted in red while engine running....747
E-11 Engine coolant temperature gauge does not indicate normally....748
E-12 Hydraulic oil temperature gauge does not indicate normally....750
E-13 Fuel level gauge does not operate normally....751
E-14 Swing lock monitor does not indicate normally....752
E-15 When monitor switch is operated, monitor displays nothing....754
E-16 Windshield wiper does not operate....756
E-17 Machine push-up function does not operate normally....760
E-18 Monitoring function fails to display boom RAISE normally....762
E-19 Monitoring function fails to display boom LOWER normally....764
E-20 Monitoring function fails to display arm IN normally....766
E-21 Monitoring function fails to display arm OUT normally....768
E-22 Monitoring function fails to display bucket CURL normally....770
E-23 Monitoring function fails to display bucket DUMP normally....772
E-24 Monitoring function fails to display swing normally....774
E-25 Monitoring function fails to display travel normally....776
E-26 Monitoring function fails to display travel differential pressure normally....778
E-27 Monitoring function fails to display service normally....780
E-28 The KOMTRAX system does not operate normally....782
E-29 Air conditioner does not operate....784
E-30 Travel alarm does not sound or does not stop sounding....786
E-31 Horn does not sound....788
Troubleshooting of hydraulic and mechanical system (H-mode)....791
System chart for hydraulic and mechanical system....794
Information contained in troubleshooting table....796
H-1 All work equipment lack power, or travel and swing speeds are slow....798
H-2 Engine speed sharply drops or engine stalls....800
H-3 No work equipment, swing or travel move....801
H-4 Abnormal noise is heard from around hydraulic pump....801
H-5 Auto-decelerator does not work....802
H-6 Fine control mode does not function or responds slow....802
H-7 Boom moves slowly or lacks power....803
H-8 Arm moves slowly or lacks power....804
H-9 Bucket moves slowly or lacks power....805
H-10 Work equipment does not move in its single operation....805
H-11 Work equipment has a bit too fast hydraulic drift....806