Komatsu PC400-6, PC400LC-6, PC450-6, PC450LC-6 Hydraulic Excavator Shop Manual - SEBM014508 PDF

Komatsu PC400-6 PC400LC-6 PC450-6 PC450LC-6 Excavator Shop Manual SEBM014508 – PDF DOWNLOAD

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Komatsu PC400-6 PC400LC-6 PC450-6 PC450LC-6 Excavator Shop Manual SEBM014508 – PDF DOWNLOAD 

Language : English
Pages : 841
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC400-6 PC400LC-6 PC450-6 PC450LC-6 Excavator Shop Manual SEBM014508 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
PC400-6                       32001 and up
PC400LC-6                  32001 and up
PC450-6                      12001 and up
PC450LC-6                  12001 and up

COVER 1
CONTENTS 2
01 GENERAL 28
SPECIFICATION DRAWINGS 29
SPECIFICATIONS 32
WEIGHT TABLE 38
FUEL, COOLANT AND LUBRICANTS 44
10 STRUCTURE AND FUNCTION 46
PARTS RELATED TO ENGINE 47
RADIATOR, OIL COOLER 49
POWER TRAIN 50
FINAL DRIVE 51
SWING CIRCLE 52
SWING MACHINERY 54
TRACK FRAME, RECOIL SPRING 55
TRACK SHOE 56
HYDRAULIC PIPING DRAWING 57
HYDRAULIC TANK, HYDRAULIC FILTER 61
HYDRAULIC PUMP 62
CONTROL VALVE 81
SELF-REDUCING PRESSURE VALVE 92
SUCTION SAFETY VALVE 97
CLSS 98
SWING MOTOR 154
CENTER SWIVEL JOINT 160
TRAVEL MOTOR 162
VALVE CONTROL 171
WORK EQUIPMENT・SWING PPC VALVE 172
TRAVEL PPC VALVE 176
SERVICE PPC VALVE 180
PPC SAFETY LOCK VALVE 183
PPC ACCUMULATOR 183
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE 184
LS-EPC VALVE 191
SOLENOID VALVE 192
BOOM HOLDING VALVE 194
WORK EQUIPMENT 197
AIR CONDITIONER 198
ACTUAL ELECTRIC WIRING DIAGRAM 199
ENGINE CONTROL 203
ELECTRONIC CONTROL SYSTEM 209
MACHINE MONITOR SYSTEM 234
FRONT WINDOW AUTO PULL-UP SYSTEM 244
20 TESTING AND ADJUSTING 246
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 247
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 248
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 264
TESTING AND ADJUSTING 272
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 273
MEASURING ENGINE SPEED 274
MEASURING EXHAUST COLOR 275
ADJUSTING VALVE CLEARANCE 276
MEASURING COMPRESSION PRESSURE 277
MEASURING BLOW-BY PRESSURE 277
TESTING AND ADJUSTING FUEL INJECTION TIMING 278
MEASURING ENGINE OIL PRESSURE 280
TESTING AND ADJUSTING FAN BELT TENSION 281
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 281
ADJUSTING ENGINE SPEED SENSOR 282
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 283
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE 284
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 285
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 289
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE 292
TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED) 297
TESTING SOLENOID VALVE OUTPUT PRESSURE 298
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE 301
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 303
TESTING TRAVEL DEVIATION 304
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 305
MEASURING OIL LEAKAGE 307
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 309
TESTING CLEARANCE OF SWING CIRCLE BEARING 310
TESTING WEAR OF SPROCKET 311
TESTING AND ADJUSTING TRACK SHOE TENSION 312
BLEEDING AIR 313
TROUBLESHOOTING 315
POINTS TO REMEMBER WHEN TROUBLESHOOTING 316
SEQUENCE OF EVENTS IN TROUBLESHOOTING 317
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 318
CHECKS BEFORE TROUBLESHOOTING 326
CONNECTOR TYPES AND MOUNTING LOCATIONS 327
CONNECTOR ARRANGEMENT DIAGRAM 329
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 332
EXPLANATION OF CONTROL MECHANISM OF ELECTRICAL SYSTEM 342
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL 343
METHOD OF USING JUDGEMENT TABLE 352
METHOD OF USING TROUBLESHOOTING CHARTS 354
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE 356
SERVICE CODE TABLE 361
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE) 362
N-1 [E218] COMMUNICATION ABNORMALITY 363
TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE) 365
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER SYSTEM 366
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 367
JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS 371
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM 373
E-1 ABNORMALITY IN ENGINE THROTTLE, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF) 375
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED 376
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED 377
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED 378
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED 379
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED 380
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED 381
E-8 ENGINE DOES NOT START 382
E-9 ENGINE SPEED IS IRREGULAR 384
a) IDLING SPEED IS IRREGULAR 384
b) THERE IS HUNTING 386
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW) 388
E-11 ENGINE DOES NOT STOP 390
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP) 392
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 394
METHOD OF USING TROUBLESHOOTING CHARTS 395
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 399
S-2 ENGINE DOES NOT START 400
(1) ENGINE DOES NOT TURN 400
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 401
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 402
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 403
S-4 ENGINE STOPS DURING OPERATIONS 404
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 405
S-6 ENGINE LACKS OUTPUT (NO POWER) 406
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 407
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 408
S-9 OIL BECOMES CONTAMINATED QUICKLY 409
S-10 FUEL CONSUMPTION IS EXCESSIVE 410
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 411
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 412
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 413
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 414
S-15 ABNORMAL NOISE IS MADE 415
S-16 VIBRATION IS EXCESSIVE 416
TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE) 417
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM 418
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 419
JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS 427
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE 429
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF) 431
C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED 432
C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED 434
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED 436
C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED 438
C-6 [E207] SHORT CIRCUIT IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED 440
C-7 [E208] DISCONNECTION IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED 441
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED 442
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED 444
C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED 446
C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED 447
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED 448
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED 449
C-14 [E231] SHORT CIRCUIT IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED 450
C-15 [E235] DISCONNECTION IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED 451
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED 452
C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED 454
C-18 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED 455
C-19 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED 456
C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED 457
C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED 458
C-22 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED 459
C-23 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED) 460
TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE) 462
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE 463
F-1 BIT PATTERN 20-(1) (SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP 465
F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP 466
F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP 467
F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP 468
F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP 469
F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP 470
F-7 BIT PATTERN 21-(1) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP 471
F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP 472
F-9 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP 473
F-10 BIT PATTERN 22-(5) (KEROSENE MODE CONNECTION) DOES NOT LIGHT UP 474
F-11 BIT PATTERN 22-(6) (L H KNOB SWITCH) DOES NOT LIGHT UP 475
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 476
PUMP MERGE/DIVIDER LOGIC, SOLENOID ACTUATION TABLE 478
TABLE OF FAILURE MODES AND CAUSES 479
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER 483
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 485
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE 486
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP) 486
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE) 487
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 487
H-7 BOOM IS SLOW OR LACKS POWER 488
H-8 ARM IS SLOW OR LACKS POWER 490
H-9 BUCKET IS SLOW OR LACKS POWER 492
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET)DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL) 493
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET) 493
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) 494
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED 494
H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED 495
H-15 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION 495
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 495
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW 496
H-18 IN SWING + ARM, ARM IS SLOW 496
H-19 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY 496
H-20 TRAVEL DEVIATION 497
a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL 497
b) EXCESSIVE TRAVEL DEVIATION WHEN STARTING 497
H-21 TRAVEL SPEED IS SLOW 498
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER 500
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED 502
H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) 502
H-25 DOES NOT SWING 503
a) DOES NOT SWING TO EITHER LEFT OR RIGHT 503
b) DOES NOT SWING IN ONE DIRECTION 503
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW 504
a) SWING ACCELERATION IS POOR 504
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING 506
a) ONE DIRECTION ONLY 506
b) BOTH DIRECTIONS 506
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 507
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 507
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING 508
a) WHEN SWING HOLDING BRAKE IS RELEASED 508
b) WHEN SWING HOLDING BRAKE IS APPLIED 508
H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED 509
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 510
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 512
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM 514
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED, E[102] ERROR IN CLOCK DATA IS DISPLAYED 518
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED 519
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED 520
M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED 520
M-5 [E108] ENGINE WATER TEMPERATURE 105℃ DETECTED IS DISPLAYED 521
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS 522
a) NONE OF LAMPS ON MONITOR PANEL LIGHT UP 522
b) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP 522
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT 524
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL) 524
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH 525
a) (COOLANT LEVEL) FLASHES 525
b) (ENGINE OIL LEVEL) FLASHES 526
c) (HYDRAULIC OIL LEVEL) FLASHES 527
M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP 528
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH 529
a) ALTERNATOR SYSTEM 529
b) ENGINE OIL PRESSURE SYSTEM 530
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH 531
a) ALTERNATOR SYSTEM 531
b) ENGINE OIL PRESSURE SENSOR SYSTEM 532
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH 533
a) (ENGINE OIL PRESSURE) FLASHES 533
b) (COOLANT LEVEL) FLASHES 533
c) (BATTERY CHARGE) FLASHES 533
d) (COOLANT TEMPERATURE) FLASHES 534
e) (FUEL LEVEL) FLASHES 534
f) (AIR CLEANER CLOGGING) FLASHES 535
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND 536
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS 536
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL) 537
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE 538
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY 538
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL 539
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY 539
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP 540
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH 540
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING 541
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED 541
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM 542
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM 543
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM 544
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM 545
M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM 546
M-30 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113) 547
a) WIPER DOES NOT WORK 547
b) WIPER SWITCH IS NOT BEING OPERATED BUT WIPER IS ACTUATED 552
M-31 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114) 553
a) WASHER MOTOR DOES NOT WORK 553
b) SWITCH IS NOT BEING OPERATED BUT WASHER IS ACTUATED 554
M-32 ELECTRIC GREASE GUN DOES NOT WORK 556
30 DISASSEMBLY AND ASSEMBLY 557
METHOD OF USING MANUAL 559
PRECAUTIONS WHEN CARRYING OUT OPERATION 561
SPECIAL TOOL LIST 563
SKETCHES OF SPECIAL TOOLS 569
STARTING MOTOR ASSEMBLY 577
REMOVAL AND INSTALLATION 577
ALTERNATOR ASSEMBLY 578
REMOVAL AND INSTALLATION 578
ENGINE OIL COOLER ASSEMBLY 579
REMOVAL AND INSTALLATION 579
FUEL INJECTION PUMP ASSEMBLY 580
REMOVAL 580
INSTALLATION 582
WATER PUMP ASSEMBLY 583
REMOVAL AND INSTALLATION 583
NOZZLE HOLDER ASSEMBLY 584
REMOVAL AND INSTALLATION 584
TURBOCHARGER ASSEMBLY 585
REMOVAL AND INSTALLATION 585
THERMOSTAT ASSEMBLY 586
REMOVAL AND INSTALLATION 586
ENGINE FRONT SEAL 587
REMOVAL AND INSTALLATION 587
ENGINE REAR SEAL 588
REMOVAL 588
INSTALLATION 589
CYLINDER HEAD ASSEMBLY 592
REMOVAL 592
INSTALLATION 596
GOVERNOR MOTOR ASSEMBLY 599
REMOVAL 599
INSTALLATION 599
AFTERCOOLER CORE ASSEMBLY 600
REMOVAL AND INSTALLATION 600
HYDRAULIC COOLER ASSEMBLY 601
REMOVAL 601
INSTALLATION 602
RADIATOR, HYDRAULIC COOLER ASSEMBLY 603
REMOVAL 603
INSTALLATION 605
ENGINE, MAIN PUMP ASSEMBLY 606
REMOVAL 606
INSTALLATION 609
DAMPER ASSEMBLY 610
REMOVAL AND INSTALLATION 610
FUEL TANK ASSEMBLY 611
REMOVAL AND INSTALLATION 611
CENTER SWIVEL JOINT ASSEMBLY 612
REMOVAL AND INSTALLATION 612
DISASSEMBLY AND ASSEMBLY 614
FINAL DRIVE ASSEMBLY 616
REMOVAL AND INSTALLATION 616
DISASSEMBLY 617
ASSEMBLY 621
TRAVEL MOTOR ASSEMBLY 627
DISASSEMBLY 627
ASSEMBLY 632
SPROCKET 643
REMOVAL AND INSTALLATION 643
SWING MOTOR ASSEMBLY 644
REMOVAL AND INSTALLATION 644
DISASSEMBLY 645
ASSEMBLY 648
SWING MACHINERY ASSEMBLY 655
REMOVAL AND INSTALLATION 655
DISASSEMBLY 656
ASSEMBLY 660
REVOLVING FRAME ASSEMBLY 665
REMOVAL 665
INSTALLATION 666
SWING CIRCLE ASSEMBLY 667
REMOVAL AND INSTALLATION 667
IDLER, RECOIL SPRING ASSEMBLY 668
REMOVAL AND INSTALLATION 668
IDLER ASSEMBLY 669
DISASSEMBLY 669
ASSEMBLY 670
RECOIL SPRING ASSEMBLY 672
DISASSEMBLY 672
ASSEMBLY 673
TRACK ROLLER ASSEMBLY 674
REMOVAL AND INSTALLATION 674
DISASSEMBLY 675
ASSEMBLY 676
CARRIER ROLLER ASSEMBLY 678
REMOVAL AND INSTALLATION 678
DISASSEMBLY 679
ASSEMBLY 681
TRACK SHOE ASSEMBLY 683
REMOVAL AND INSTALLATION 683
HYDRAULIC TANK ASSEMBLY 684
REMOVAL 684
INSTALLATION 685
MAIN PUMP ASSEMBLY 686
REMOVAL 686
INSTALLATION 687
DISASSEMBLY 688
ASSEMBLY 694
MAIN PUMP INPUT SHAFT OIL SEAL 709
REMOVAL AND INSTALLATION 709
CONTROL VALVE ASSEMBLY 710
REMOVAL 710
INSTALLATION 712
DISASSEMBLY 713
ASSEMBLY 719
PUMP MERGE/DIVIDER VALVE ASSEMBLY 726
DISASSEMBLY AND ASSEMBLY 726
PRESSURE COMPENSATION VALVE ASSEMBLY 727
DISASSEMBLY AND ASSEMBLY 727
SERVO VALVE ASSEMBLY FOR FRONT PUMP 728
REMOVAL AND INSTALLATION 728
SERVO VALVE ASSEMBLY FOR REAR PUMP 729
REMOVAL AND INSTALLATION 729
LS-EPC SOLENOID VALVE ASSEMBLY 730
REMOVAL AND INSTALLATION 730
SOLENOID VALVE ASSEMBLY 731
REMOVAL AND INSTALLATION 731
WORK EQUIPMENT PPC VALVE ASSEMBLY 732
REMOVAL AND INSTALLATION 732
DISASSEMBLY 733
ASSEMBLY 734
TRAVEL PPC VALVE ASSEMBLY 735
REMOVAL AND INSTALLATION 735
DISASSEMBLY 736
ASSEMBLY 737
PPC SHUTTLE VALVE ASSEMBLY 738
REMOVAL 738
INSTALLATION 739
DISASSEMBLY 740
ASSEMBLY 741
BOOM LOCK VALVE ASSEMBLY 742
REMOVAL AND INSTALLATION 742
DISASSEMBLY AND ASSEMBLY 743
BOOM CYLINDER ASSEMBLY 744
REMOVAL 744
INSTALLATION 745
ARM CYLINDER ASSEMBLY 746
REMOVAL 746
INSTALLATION 747
BUCKET CYLINDER ASSEMBLY 748
REMOVAL 748
INSTALLATION 749
HYDRAULIC CYLINDER ASSEMBLY 750
DISASSEMBLY 750
ASSEMBLY 753
WORK EQUIPMENT ASSEMBLY 757
REMOVAL 757
INSTALLATION 758
BUCKET ASSEMBLY 759
REMOVAL 759
INSTALLATION 760
ARM ASSEMBLY 761
REMOVAL 761
INSTALLATION 762
BUCKET, ARM ASSEMBLY 763
REMOVAL 763
INSTALLATION 764
BOOM ASSEMBLY 765
REMOVAL 765
INSTALLATION 766
OPERATOR’S CAB ASSEMBLY 767
REMOVAL 767
INSTALLATION 768
COUNTERWEIGHT ASSEMBLY 769
REMOVAL AND INSTALLATION 769
AIR CONDITIONER COMPRESSOR ASSEMBLY 770
REMOVAL AND INSTALLATION 770
CONDENSER ASSEMBLY 771
REMOVAL AND INSTALLATION 771
RECEIVER TANK ASSEMBLY 772
REMOVAL AND INSTALLATION 772
AIR CONDITIONER UNIT ASSEMBLY 773
REMOVAL 773
INSTALLATION 774
GOVERNOR, PUMP CONTROLLER ASSEMBLY 775
REMOVAL AND INSTALLATION 775
MONITOR PANEL ASSEMBLY 776
REMOVAL AND INSTALLATION 776
CONTROL STAND CASE 777
REMOVAL 777
INSTALLATION 778
40 MAINTENANCE STANDARD 779
ENGINE MOUNT 780
SWING MACHINERY 781
SWING CIRCLE 783
FINAL DRIVE 785
SPROCKET 787
TRACK FRAME AND RECOIL SPRING 789
IDLER 790
CARRIER ROLLER 792
TRACK ROLLER 793
TRACK SHOE 794
HYDRAULIC PUMP 798
CONTROL VALVE 799
SELF-REDUCING PRESSURE VALVE 806
SUCTION-SAFETY VALVE 807
SWING MOTOR 808
TRAVEL MOTOR 809
WORK EQUIPMENT・SWING PPC VALVE 810
TRAVEL PPC VALVE 811
SERVICE PPC VALVE 812
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE 813
LS-EPC VALVE 814
SOLENOID VALVE 815
CENTER SWIVEL JOINT 816
BOOM HOLDING VALVE 818
HYDRAULIC CYLINDER 819
WORK EQUIPMENT 822
DIMENSIONS OF WORK EQUIPMENT 826
90 OTHERS 830
HYDRAULIC CIRCUIT DIAGRAM 831
BACK HOE 831
LOADING SHOVEL 832
ELECTRIC CIRCUIT DIAGRAM 833
BACK HOE 833
ELECTRIC CIRCUIT DIAGRAM (1/3) WITH POWER WINDOW 833
ELECTRIC CIRCUIT DIAGRAM (2/3) WITH POWER WINDOW 834
ELECTRIC CIRCUIT DIAGRAM (3/3) WITH POWER WINDOW 835
ELECTRIC CIRCUIT DIAGRAM (1/3) PC400-6 SERIAL NO : 32250 AND UP PC450-6 SERIAL NO : 12144 AND UP WITHOUT POWER WINDOW 836
ELECTRIC CIRCUIT DIAGRAM (2/3) PC400-6 SERIAL NO : 32250 AND UP PC450-6 SERIAL NO : 12144 AND UP WITHOUT POWER WINDOW 837
ELECTRIC CIRCUIT DIAGRAM (3/3) PC400-6 SERIAL NO : 32250 AND UP PC450-6 SERIAL NO : 12144 AND UP WITHOUT POWER WINDOW 838
LOADING SHOVEL 839
ELECTRIC CIRCUIT DIAGRAM (1/3) 839
ELECTRIC CIRCUIT DIAGRAM (2/3) 840
ELECTRIC CIRCUIT DIAGRAM (1/3) 841

DESCRIPTION:

Komatsu PC400-6 PC400LC-6 PC450-6 PC450LC-6 Excavator Shop Manual SEBM014508 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
PC400-6                       32001 and up
PC400LC-6                  32001 and up
PC450-6                      12001 and up
PC450LC-6                  12001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.● Always wear safety glasses when hitting parts with a hammer.● Always wear safety glasses when grinding parts with a grinder, etc.3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.