Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC400-6, PC400LC-6, PC450-6, PC450LC-6, PC400-7, PC400LC-7, PC450-7, PC450LC-7, PC400-8, PC400LC-8, PC450-8, PC450LC-8, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC400-6, PC400LC-6, PC450-6, PC450LC-6, PC400-7, PC400LC-7, PC450-7, PC450LC-7, PC400-8, PC400LC-8, PC450-8, PC450LC-8 workshop service repair manual includes:
* 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: 7,533 pages
File Format: PDF
Language: English
SEBM014508 – Hydraulic Excavator PC400-6, PC400LC-6, PC450-6, PC450LC-6 Shop Manual.pdf
SEBM023600 – Hydraulic Excavator PC400-6, PC400LC-6, PC450-6, PC450LC-6 Shop Manual Supplement.pdf
SEBM033000 – Hydraulic Excavator PC400-7, PC400LC-7, PC450-7, PC450LC-7 Shop Manual.pdf
SEBM033007 – Hydraulic Excavator PC400-7, PC400LC-7, PC450-7, PC450LC-7 Shop Manual.pdf
SEBM033012 – Hydraulic Excavator PC400-7, PC400LC-7, PC450-7, PC450LC-7 Shop Manual.pdf
SEN02223-05 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Shop Manual.pdf
SEN02223-12 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Shop Manual.pdf
SEAM009102T – Hydraulic Excavator PC400-6, PC400LC-6, PC450-6, PC450LC-6 Operation & Maintenance Manual.pdf
SEAM051900T – Hydraulic Excavator PC400-6, PC400LC-6, PC450-6, PC450LC-6 Operation & Maintenance Manual.pdf
SEAM056502 – Hydraulic Excavator GALEO PC400-7, PC400LC-7, PC450-7, PC450LC-7 Operation & Maintenance Manual.pdf
TEN00038-03 – Hydraulic Excavator PC400-7, PC400LC-7, PC450-7, PC450LC-7 Operation & Maintenance Manual.pdf
TEN00039-03 – Hydraulic Excavator GALEO PC400-7, PC400LC-7, PC450-7, PC450LC-7 Operation & Maintenance Manual.pdf
TEN00184-03 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Operation & Maintenance Manual.pdf
TEN00336-01 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Operation & Maintenance Manual.pdf
TEN00499-02 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Operation & Maintenance Manual.pdf
SEAM009102T – Hydraulic Excavator PC400-6, PC400LC-6, PC450-6, PC450LC-6 Operation & Maintenance Manual…..2
COVER…..2
1.FOREWORD…..3
2.SAFETY INFORMATION…..4
3.INTRODUCTION…..5
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR…..6
5.CONTENTS…..7
SAFETY…..11
6.GENERAL PRECAUTIONS…..12
7.PRECAUTIONS DURING OPERATION…..21
7.1 BEFORE STARTING ENGINE…..21
7.2 AFTER STARTING ENGINE…..23
7.3 TRANSPORTATION…..31
7.4 BATTERY…..33
7.5 TOWING…..35
7.6 BUCKET WITH HOOK…..36
8.PRECAUTIONS FOR MAINTENANCE…..37
8.1 BEFORE CARRYING OUT MAINTENANCE…..37
8.2 DURING MAINTENANCE…..42
9.POSITION FOR ATTACHING SAFETY LABELS…..49
OPERATION…..54
10.GENERAL VIEW…..55
10.1 GENERAL VIEW OF MACHINE…..55
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…..56
11.EXPLANATION OF COMPONENTS…..57
11.1 MACHINE MONITOR…..57
11.2 SWITCHES…..68
11.3 CONTROL LEVERS,PEDALS…..72
11.4 CEILING WINDOW…..77
11.5 FRONT WINDOW…..78
11.6 DOOR LOCK…..80
11.7 CAP,COVER WITH LOCK…..81
11.8 HOT AND COOL BOX…..82
11.9 LUGGAGE BOX…..82
11.10 ASHTRAY…..82
11.11 HANDLING AIR CONDITIONER…..83
11.12 CAR RADIO…..86
11.13 ELECTRIC POWER TAKE-OUT ADAPTER…..90
11.14 FUSE…..91
11.15 FUSIBLE LINK…..92
11.16 CONTROLLERS…..92
11.17 TOOL BOX…..92
11.18 GREASE GUN HOLDER…..92
11.19 HANDLING ACCUMULATOR…..93
12.OPERATION…..94
12.1 CHECK BEFORE STARTING ENGINE…..94
12.2 STARTING ENGINE…..105
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…..108
12.4 MOVING MACHINE OFF…..114
12.5 STEERING MACHINE…..117
12.6 STOPPING MACHINE…..119
12.7 SWINGING…..120
12.8 OPERATION OF WORK EQUIPMENT…..121
12.9 HANDLING ACTIVE MODE…..122
12.10 HANDLING WORKING MODE…..123
12.11 PROHIBITIONS FOR OPERATION…..125
12.12 PRECAUTIONS FOR OPERATION…..127
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…..128
12.14 HOW TO ESCAPE FROM MUD…..130
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…..131
12.16 REPLACEMENT AND INVERSION OF BUCKET…..132
12.17 PARKING MACHINE…..134
12.18 CHECK AFTER FINISHING WORK…..135
12.19 STOPPING ENGINE…..136
12.20 CHECK AFTER STOPPING ENGINE…..137
12.21 LOCKING…..137
13.TRANSPORTATION…..138
13.1 TRANSPORTATION PROCEDURE…..138
13.2 LOADING,UNLOADING WORK WITH TRAILERS…..139
13.3 METHOD OF LIFTING MACHINE…..145
14.COLD WEATHER OPERATION…..146
14.1 PRECAUTIONS FOR LOW TEMPERATURE…..146
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…..148
14.3 AFTER COLD WEATHER…..148
15.LONG-TERM STORAGE…..149
15.1 BEFORE STORAGE…..149
15.2 DURING STORAGE…..150
15.3 AFTER STORAGE…..150
15.4 STARTING MACHINE AFTER LING-TERM STORAGE…..150
16.TROUBLESHOOTING…..151
16.1 PHENOMENA THAT ARE NOT FAILURES…..151
16.2 METHOD OF TOWING MACHINE…..151
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…..151
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…..152
16.5 IF BATTERY IS DISCHARGED…..152
16.6 OTHER TROUBLE…..157
MAINTENANCE …..162
17.GUIDES TO MAINTENANCE…..163
18.OUTLINES OF SERVICE…..166
18.1 OUTLINE OF OIL,FUEL,COOLANT…..166
18.2 OUTLINE OF ELECTRIC SYSTEM…..169
18.3 OUTLINE OF HYDRAULIC SYSTEM…..170
19.WEAR PARTS LIST…..171
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..173
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..177
21.1 INTRODUCTION OF NECESSARY TOOLS…..177
21.2 TORQUE LIST…..178
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..179
23.MAINTENANCE SCHEDULE CHART…..181
23.1 MAINTENANCE SCHEDULE CHART…..181
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…..183
24.SERVICE PROCEDURE…..184
24.1 INITIAL 250 HOURS SERVICE…..184
24.2 WHEN REQUIRED…..185
24.3 CHECK BEFORE STARTING…..203
24.4 EVERY 50 HOURS SERVICE…..207
24.5 EVERY 100 HOURS SERVICE…..209
24.6 EVERY 250 HOURS SERVICE…..211
24.7 EVERY 500 HOURS SERVICE…..217
24.8 EVERY 1000 HOURS SERVICE…..225
24.9 EVERY 2000 HOURS SERVICE…..228
24.10 EVERY 4000 HOURS SERVICE…..231
24.11 EVERY 5000 HOURS SERVICE…..232
SPECIFICATIONS…..236
25.SPECIFICATIONS…..237
OPTIONS,ATTACHMENTS…..243
26.GENERAL PRECAUTIONS…..244
26.1 PRECAUTIONS RELATED TO SAFETY…..244
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..245
27.HANDLING BUCKET WITH HOOK…..246
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…..246
27.2 PROHIBITED OPERATIONS…..246
27.3 PRECAUTIONS DURING OPERATIONS…..246
28.USING SEAT BELT…..247
28.1 SEAT BELT…..247
29.HANDLING CAR HEATER…..249
29.1 GENERAL LOCATIONS…..249
29.2 PRECAUTION FOR CAR HEATER…..250
30.MACHINES READY FOR ATTACHMENT…..251
30.1 GENERAL LOCATIONS…..251
30.2 HYDRAULIC CIRCUIT…..253
30.3 PROCEDURE FOR REMOVAL AND INSTALLATION OF ATTACHMENT…..255
30.4 OPERATION…..257
30.5 LONG TERM STORAGE…..258
30.6 SPECIFICATIONS…..258
31.INTRODUCTION OF ATTACHMENTS…..259
31.1 SPECIFICATION,USE…..259
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…..261
31.3 SELECTION OF TRACK SHOES…..263
31.4 SELECTION OF BUCKET TEETH…..264
32.EXTENDING MACHINE SERVICE LIFE…..265
32.1 HYDRAULIC BREAKER…..265
32.2 POWER RIPPER…..269
32.3 FORK GRAB…..270
32.4 GRAPPLE BUCKET…..271
32.5 SCRAP GRAPPLE…..272
32.6 CRUSHER AND CUTTER…..273
32.7 HYDRAULIC PILE DRIVER…..274
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE…..275
33.AUTO-GREASING SYSTEM…..276
33.1 AUTO GREASING CONTROLLER…..276
33.2 ACTION WHEN ABNORMALITY OCCURS…..277
33.3 CHECK BEFORE STARTING…..278
33.4 EVERY 50 HOURS SERVICE…..280
SEAM051900T – Hydraulic Excavator PC400-6, PC400LC-6, PC450-6, PC450LC-6 Operation & Maintenance Manual…..282
COVER…..282
1. FOREWORD…..283
2. SAFETY INFORMATION…..286
3. INTRODUCTION…..287
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..288
5. CONTENTS…..289
SAFETY…..293
6. GENERAL PRECAUTIONS …..294
7. PRECAUTIONS DURING OPERATION…..303
7.1 BEFORE STARTING ENGINE…..303
7.2 AFTER STARTING ENGINE…..305
7.3 TRANSPORTATION…..313
7.4 BATTERY…..315
7.5 TOWING…..317
7.6 BUCKET WITH HOOK…..318
8. PRECAUTIONS FOR MAINTENANCE…..319
8.1 BEFORE CARRYING OUT MAINTENANCE…..319
8.2 DURING MAINTENANCE…..324
9. POSITION FOR ATTACHING SAFETY LABELS…..331
OPERATION…..336
10. GENERAL VIEW …..337
10.1 GENERAL VIEW OF MACHINE…..337
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…..338
11. EXPLANATION OF COMPONENTS…..339
11.1 MACHINE MONITOR…..339
11.2 SWITCHES …..350
11.3 CONTROL LEVERS, PEDALS…..354
11.4 CEILING WINDOW…..359
11.5 FRONT WINDOW…..360
11.6 DOOR LOCK…..362
11.7 CAP, COVER WITH LOCK…..363
11.8 HOT AND COOL BOX…..364
11.9 LUGGAGE BOX…..364
11.10 ASHTRAY…..364
11.11 HANDLING AIR CONDITIONER…..365
11.12 CAR RADIO…..368
11.13 ELECTRIC POWER TAKE-OUT ADAPTER…..372
11.14 FUSE…..373
11.15 FUSIBLE LINK…..374
11.16 CONTROLLERS…..374
11.17 TOOL BOX…..374
11.18 GREASE GUN HOLDER…..374
11.19 HANDLING ACCUMULATOR…..375
12. OPERATION…..376
12.1 CHECK BEFORE STARTING ENGINE…..376
12.2 STARTING ENGINE…..387
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…..390
12.4 MOVING MACHINE OFF…..396
12.5 STEERING MACHINE…..399
12.6 STOPPING MACHINE…..401
12.7 SWINGING…..402
12.8 OPERATION OF WORK EQUIPMENT…..403
12.9 HANDLING ACTIVE MODE…..404
12.10 HANDLING WORKING MODE…..405
12.11 PROHIBITIONS FOR OPERATION…..407
12.12 PRECAUTIONS FOR OPERATION…..409
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…..410
12.14 HOW TO ESCAPE FROM MUD…..412
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…..413
12.16 REPLACEMENT AND INVERSION OF BUCKET…..414
12.17 PARKING MACHINE…..416
12.18 CHECK AFTER FINISHING WORK…..417
12.19 STOPPING ENGINE…..418
12.20 CHECK AFTER STOPPING ENGINE…..419
12.21 LOCKING…..419
13. TRANSPORTATION…..420
13.1 TRANSPORTATION PROCEDURE…..420
13.2 LOADING, UNLOADING WORK WITH TRAILERS…..421
13.3 METHOD OF LIFTING MACHINE…..427
14. COLD WEATHER OPERATION…..428
14.1 PRECAUTIONS FOR LOW TEMPERATURE…..428
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…..430
14.3 AFTER COLD WEATHER…..430
15. LONG-TERM STORAGE…..431
15.1 BEFORE STORAGE…..431
15.2 DURING STORAGE…..432
15.3 AFTER STORAGE…..432
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…..432
16. TROUBLESHOOTING…..433
16.1 PHENOMENA THAT ARE NOT FAILURES…..433
16.2 METHOD OF TOWING MACHINE…..433
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…..433
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…..434
16.5 IF BATTERY IS DISCHARGED…..434
16.6 OTHER TROUBLE…..439
MAINTENANCE…..444
17. GUIDES TO MAINTENANCE…..445
18. OUTLINES OF SERVICE…..448
18.1 OUTLINE OF OIL,FUEL,COOLANT…..448
18.2 OUTLINE OF ELECTRIC SYSTEM…..451
18.3 OUTLINE OF HYDRAULIC SYSTEM…..452
19. WEAR PARTS LIST…..453
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..455
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..459
21.1 INTRODUCTION OF NECESSARY TOOLS…..459
21.2 TORQUE LIST…..460
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..461
23. MAINTENANCE SCHEDULE CHART…..463
23.1 MAINTENANCE SCHEDULE CHART…..463
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…..465
24. SERVICE PROCEDURE…..466
24.1 INITIAL 250 HOURS SERVICE…..466
24.2 WHEN REQUIRED…..467
24.3 CHECK BEFORE STARTING…..485
24.4 EVERY 50 HOURS SERVICE…..489
24.5 EVERY 100 HOURS SERVICE…..491
24.6 EVERY 250 HOURS SERVICE…..493
24.7 EVERY 500 HOURS SERVICE…..499
24.8 EVERY 1000 HOURS SERVICE…..507
24.9 EVERY 2000 HOURS SERVICE…..510
24.10 EVERY 4000 HOURS SERVICE…..513
24.11 EVERY 5000 HOURS SERVICE…..514
SPECIFICATIONS…..518
25. SPECIFICATIONS…..519
OPTIONS, ATTACHMENTS…..525
26. GENERAL PRECAUTIONS…..526
26.1 PRECAUTIONS RELATED TO SAFETY…..526
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..527
27. HANDLING BUCKET WITH HOOK…..528
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…..528
27.2 PROHIBITED OPERATIONS…..528
27.3 PRECAUTIONS DURING OPERATIONS…..528
28. USING SEAT BELT…..529
28.1 SEAT BELT…..529
29. HANDLING CAR HEATER…..531
29.1 GENERAL LOCATIONS…..531
29.2 PREPARATION FOR CAR HEATER…..532
30. MACHINES READY FOR ATTACHMENT …..533
30.1 GENERAL LOCATIONS…..533
30.2 HYDRAULIC CIRCUIT…..535
30.3 PROCEDURE FOR REMOVAL AND INSTALLATION OF ATTACHMENT …..537
30.4 OPERATION…..539
30.5 LONG TERM STORAGE…..540
30.6 SPECIFICATIONS…..540
31. INTRODUCTION OF ATTACHMENTS…..541
31.1 SPECIFICATION, USE…..541
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…..543
31.3 SELECTION OF TRACK SHOES…..545
31.4 SELECTION OF BUCKET TEETH…..546
32. EXTENDING MACHINE SERVICE LIFE…..547
32.1 HYDRAULIC BREAKER…..547
32.2 POWER RIPPER…..551
32.3 FORK GRAB…..552
32.4 GRAPPLE BUCKET…..553
32.5 SCRAP GRAPPLE…..554
32.6 CRUSHER AND CUTTER…..555
32.7 HYDRAULIC PILE DRIVER…..556
32.8 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE…..557
33. AUTO-GREASING SYSTEM…..558
31.1 AUTO-GREASING CONTROLLER…..558
33.2 ACTION WHEN ABNORMALITY OCCURS…..559
33.3 CHECK BEFORE STARTING…..560
33.4 EVERY 50 HOURS SERVICE…..562
SEAM056502 – Hydraulic Excavator GALEO PC400-7, PC400LC-7, PC450-7, PC450LC-7 Operation & Maintenance Manual…..564
COVER…..564
FOREWORD…..565
FOREWORD…..566
SAFETY INFORMATION…..569
INTRODUCTION…..571
DIRECTIONS OF MACHINE…..571
PRODUCT INFORMATION…..572
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..572
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..572
SERVICE METER LOCATION…..573
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..573
CONTENTS…..574
SAFETY…..577
SAFETY INFORMATION…..578
SAFETY LABELS…..580
LOCATION OF SAFETY LABELS…..580
SAFETY LABELS…..581
SAFETY INFORMATION…..586
SAFETY RULES…..586
IF ABNORMALITIES ARE FOUND…..586
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..586
FIRE EXTINGUISHER AND FIRST AID KIT…..586
SAFETY EQUIPMENT…..586
KEEP MACHINE CLEAN…..587
KEEP OPERATOR'S COMPARTMENT CLEAN…..587
LEAVING OPERATOR'S SEAT WITH LOCK…..587
HANDRAILS AND STEPS…..588
MOUNTING AND DISMOUNTING…..588
NO PERSONS ON ATTACHMENTS…..588
BURN PREVENTION…..589
FIRE PREVENTION AND EXPLOSION PREVENTION…..589
ACTION IF FIRE OCCURS…..590
WINDSHIELD WASHER FLUID…..590
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..590
ATTACHMENT INSTALLATION…..591
ATTACHMENT COMBINATIONS…..591
CAB WINDOW GLASSES…..591
UNAUTHORIZED MODIFICATIONS…..591
SAFETY AT JOBSITE…..591
WORKING ON LOOSE GROUND…..592
DISTANCE TO HIGH VOLTAGE CABLES…..592
ENSURE GOOD VISIBILITY…..592
VENTILATION FOR ENCLOSED AREA…..593
SIGNALMAN'S SIGNAL AND SIGNS…..593
EMERGENCY EXIT FROM OPERATOR'S CAB…..593
ASBESTOS DUST HAZARD PREVENTION…..593
SAFETY MACHINE OPERATION…..594
STARTING ENGINE…..594
CHECKS BEFORE STARTING ENGINE…..594
SAFETY RULES FOR STARTING ENGINE…..594
STARTING ENGINE IN COLD WEATHER…..595
OPERATION…..596
CHECKS BEFORE OPERATION…..596
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..596
SAFETY RULES FOR TRAVELING…..597
TRAVELING ON SLOPES…..597
OPERATIONS ON SLOPES…..598
PROHIBITED OPERATIONS…..598
OPERATIONS ON SNOW…..600
PARKING MACHINE…..601
TRANSPORTATION…..602
LOADING AND UNLOADING…..602
SHIPPING THE MACHINE…..602
BATTERY…..603
BATTERY HAZARD PREVENTION…..603
STARTING ENGINE WITH BOOSTER CABLES…..604
TOWING…..605
SAFETY RULES FOR TOWING…..605
LIFTING OBJECTS WITH BUCKET…..606
SAFETY RULES FOR LIFTING OBJECTS…..606
SAFETY MAINTENANCE INFORMATION…..607
WARNING TAG…..607
KEEP WORK PLACE CLEAN AND TIDY…..607
APPOINT LEADER WHEN WORKING WITH OTHERS…..607
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..608
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..608
PROPER TOOLS…..609
ACCUMULATOR…..609
PERSONNEL…..609
ATTACHMENTS…..610
WORK UNDER THE MACHINE…..610
NOISE…..610
WHEN USING HAMMER…..610
WELDING WORKS…..610
REMOVING BATTERY TERMINALS…..611
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..611
DO NOT DISASSEMBLE RECOIL SPRINGS…..611
SAFETY RULES FOR HIGH-PRESSURE OIL…..612
SAFETY HANDLING HIGH-PRESSURE HOSES…..612
WASTE MATERIALS…..612
AIR CONDITIONER MAINTENANCE…..612
COMPRESSED AIR…..613
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..613
OPERATION…..615
MACHINE VIEW ILLUSTRATIONS…..616
OVERALL MACHINE VIEW…..616
CONTROLS AND GAUGES…..617
DETAILED CONTROLS AND GAUGES…..619
MONITORING SYSTEM…..619
SWITCHES…..644
CONTROL LEVERS AND PEDALS…..649
SUN ROOF…..652
WINDSHIELD…..652
EMERGENCY EXIT FROM OPERATOR'S CAB…..657
DOOR LOCK…..657
CAP WITH LOCK…..658
HOT AND COOL BOX…..659
MAGAZINE BOX…..660
ASHTRAY…..660
AIR CONDITIONER CONTROLS…..661
RADIO…..675
AUXILIARY ELECTRIC POWER…..679
FUSE…..680
FUSIBLELINK…..681
CONTROLLERS…..681
TOOL BOX…..682
GREASE GUN HOLDER…..682
ACCUMULATOR…..683
MACHINE OPERATIONS AND CONTROLS…..684
BEFORE STARTING ENGINE…..684
STARTING ENGINE…..699
AFTER STARTING ENGINE…..703
STOPPING THE ENGINE…..712
MACHINE OPERATION…..713
STEERING THE MACHINE…..717
SWINGING…..719
WORK EQUIPMENT CONTROLS AND OPERATIONS…..720
WORKING MODE…..722
PROHIBITED OPERATIONS…..723
GENERAL OPERATION INFORMATION…..725
TRAVELING ON SLOPES…..727
ESCAPE FROM MUD…..729
RECOMMENDED APPLICATIONS…..730
BUCKET REPLACEMENT AND INVERSION…..732
PARKING MACHINE…..735
CHECK AFTER SHUT OFF ENGINE…..736
MACHINE INSPECTION AFTER DAILY WORK…..736
LOCKING…..737
TRANSPORTATION…..738
PRECAUTIONS FOR TRANSPORTATION…..738
LIFTING MACHINE…..738
PRECAUTIONS WHEN LOADING…..739
TRANSPORTATION POSTURE…..739
COLD WEATHER OPERATION…..743
COLD WEATHER OPERATION INFORMATION…..743
AFTER DAILY WORK COMPLETION…..745
AFTER COLD WEATHER SEASON…..745
LONG TERM STORAGE…..746
BEFORE STORAGE…..746
DURING STORAGE…..746
AFTER STORAGE…..746
STARTING MACHINE AFTER LONG-TERM STORAGE…..747
TROUBLES AND ACTIONS…..748
RUNNING OUT OF FUEL…..748
PHENOMENA THAT ARE NOT FAILURES…..749
TOWING THE MACHINE…..750
LIGHTWEIGHT TOWING HOLE…..750
SEVERE JOB CONDITION…..750
DISCHARGED BATTERY…..751
OTHER TROUBLE…..755
MAINTENANCE…..761
MAINTENANCE INFORMATION…..762
LUBRICANTS, COOLANT AND FILTERS…..764
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..764
ELECTRIC SYSTEM MAINTENANCE…..767
WEAR PARTS…..768
WEAR PARTS LIST…..768
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…..769
TIGHTENING TORQUE SPECIFICATIONS…..773
TIGHTENING TORQUE LIST…..773
SAFETY CRITICAL PARTS…..774
SAFETY CRITICAL PARTS LIST…..774
MAINTENANCE SCHEDULE…..775
MAINTENANCE SCHEDULE CHART…..775
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..777
MAINTENANCE PROCEDURE…..778
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..778
REPLACE FUEL FILTER CARTRIDGE…..818
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…..778
CHECK ENGINE VALVE CLEARANCE, ADJUST…..837
WHEN REQUIRED…..779
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..779
CLEAN INSIDE OF COOLING SYSTEM…..784
CHECK AND TIGHTEN TRACK SHOE BOLTS…..787
CHECK AND ADJUST TRACK TENSION…..788
CHECK ELECTRICAL INTAKE AIR HEATER…..790
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..791
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..794
REPLACE BUCKET SIDE CUTTER, SHROUD…..795
ADJUST BUCKET CLEARANCE…..796
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..797
CHECK AND ADJUST AIR CONDITIONER…..798
WASH WASHABLE FLOOR…..799
BLEEDING AIR FROM HYDRAULIC SYSTEM…..802
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..804
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit)…..805
CHECK BEFORE STARTING…..806
EVERY 250 HOURS MAINTENANCE…..807
LUBRICATING…..807
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…..808
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..809
CHECK LEVEL OF BATTERY ELECTROLYTE…..810
LUBRICATE SWING CIRCLE…..813
CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST…..813
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..815
EVERY 500 HOURS MAINTENANCE…..816
LUBRICATING…..816
REPLACE FUEL FILTER CARTRIDGE…..818
CHECK, WASH FUEL STRAINER…..820
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..821
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..822
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)…..824
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…..825
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…..826
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE…..827
EVERY 1000 HOURS MAINTENANCE…..829
REPLACE HYDRAULIC OIL FILTER ELEMENT…..829
CHANGE OIL IN SWING MACHINERY CASE…..831
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…..832
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..832
CHECK PLAY TURBOCHARGER ROTOR…..832
REPLACE CORROSION RESISTOR CARTRIDGE…..833
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT…..834
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)…..834
EVERY 2000 HOURS MAINTENANCE…..835
CHANGE OIL IN FINAL DRIVE CASE…..835
CHECK INJECTOR…..835
CLEAN HYDRAULIC TANK STRAINER…..836
CLEAN ENGINE BREATHER…..836
CLEAN, CHECK TURBOCHARGER…..837
CHECK ALTERNATOR, STARTING MOTOR…..837
CHECK ENGINE VALVE CLEARANCE, ADJUST…..837
CHECK VIBRATION DAMPER…..837
EVERY 4000 HOURS MAINTENENCE…..838
CHECK WATER PUMP…..838
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…..838
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..839
REPLACE INJECTOR NOZZLE ASSEMBLY…..839
EVERY 5000 HOURS MAINTENANCE…..840
CHANGE OIL IN HYDRAULIC TANK…..840
EVERY 8000 HOURS MAINTENANCE…..842
REPLACE HIGH-PRESSURE PIPING CLAMP…..842
REPLACE FUEL SPRAY PREVENTION CAP…..842
SPECIFICATIONS…..843
SPECIFICATIONS…..844
ATTACHMENTS, OPTIONS…..847
GENERAL PRECAUTIONS FOR SAFETY…..848
PRECAUTIONS WHEN SELECTING…..848
READ THE INSTRUCTION MANUAL THOROUGHLY…..848
PRECAUTIONS WHEN REMOVING OR INSTALLING…..848
PRECAUTIONS WHEN USING…..848
MACHINE READY FOR ATTACHMENT…..849
LOCATIONS…..849
HYDRAULIC CIRCUIT…..853
ATTACHMENT REMOVAL AND INSTALLATION…..857
ATTACHMENT OPERATIONS…..859
LONG TERM STORAGE…..861
SPECIFICATIONS…..861
ATTACHMENT GUIDE…..862
ATTACHMENT COMBINATIONS…..862
RECOMMENDED ATTACHMENT OPERATIONS…..864
HYDRAULIC BREAKER…..864
INDEX…..869
SEBM014508 – Hydraulic Excavator PC400-6, PC400LC-6, PC450-6, PC450LC-6 Shop Manual…..873
COVER…..873
CONTENTS…..874
01 GENERAL…..900
SPECIFICATION DRAWINGS…..901
SPECIFICATIONS…..904
WEIGHT TABLE…..910
FUEL, COOLANT AND LUBRICANTS…..916
10 STRUCTURE AND FUNCTION…..918
PARTS RELATED TO ENGINE…..919
RADIATOR, OIL COOLER…..921
POWER TRAIN…..922
FINAL DRIVE…..923
SWING CIRCLE…..924
SWING MACHINERY…..926
TRACK FRAME, RECOIL SPRING…..927
TRACK SHOE…..928
HYDRAULIC PIPING DRAWING…..929
HYDRAULIC TANK, HYDRAULIC FILTER…..933
HYDRAULIC PUMP…..934
CONTROL VALVE…..953
SELF-REDUCING PRESSURE VALVE…..964
SUCTION SAFETY VALVE…..969
CLSS…..970
SWING MOTOR…..1026
CENTER SWIVEL JOINT…..1032
TRAVEL MOTOR…..1034
VALVE CONTROL…..1043
WORK EQUIPMENT・SWING PPC VALVE…..1044
TRAVEL PPC VALVE…..1048
SERVICE PPC VALVE…..1052
PPC SAFETY LOCK VALVE…..1055
PPC ACCUMULATOR…..1055
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE…..1056
LS-EPC VALVE…..1063
SOLENOID VALVE…..1064
BOOM HOLDING VALVE…..1066
WORK EQUIPMENT…..1069
AIR CONDITIONER…..1070
ACTUAL ELECTRIC WIRING DIAGRAM…..1071
ENGINE CONTROL…..1075
ELECTRONIC CONTROL SYSTEM…..1081
MACHINE MONITOR SYSTEM…..1106
FRONT WINDOW AUTO PULL-UP SYSTEM…..1116
20 TESTING AND ADJUSTING…..1118
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…..1119
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…..1120
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…..1136
TESTING AND ADJUSTING…..1144
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…..1145
MEASURING ENGINE SPEED…..1146
MEASURING EXHAUST COLOR…..1147
ADJUSTING VALVE CLEARANCE…..1148
MEASURING COMPRESSION PRESSURE…..1149
MEASURING BLOW-BY PRESSURE…..1149
TESTING AND ADJUSTING FUEL INJECTION TIMING…..1150
MEASURING ENGINE OIL PRESSURE…..1152
TESTING AND ADJUSTING FAN BELT TENSION…..1153
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…..1153
ADJUSTING ENGINE SPEED SENSOR…..1154
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)…..1155
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE…..1156
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…..1157
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)…..1161
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…..1164
TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED)…..1169
TESTING SOLENOID VALVE OUTPUT PRESSURE…..1170
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE…..1173
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…..1175
TESTING TRAVEL DEVIATION…..1176
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…..1177
MEASURING OIL LEAKAGE…..1179
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…..1181
TESTING CLEARANCE OF SWING CIRCLE BEARING…..1182
TESTING WEAR OF SPROCKET…..1183
TESTING AND ADJUSTING TRACK SHOE TENSION…..1184
BLEEDING AIR…..1185
TROUBLESHOOTING…..1187
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..1188
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..1189
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..1190
CHECKS BEFORE TROUBLESHOOTING…..1198
CONNECTOR TYPES AND MOUNTING LOCATIONS…..1199
CONNECTOR ARRANGEMENT DIAGRAM…..1201
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..1204
EXPLANATION OF CONTROL MECHANISM OF ELECTRICAL SYSTEM…..1214
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL…..1215
METHOD OF USING JUDGEMENT TABLE…..1224
METHOD OF USING TROUBLESHOOTING CHARTS…..1226
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE…..1228
SERVICE CODE TABLE…..1233
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)…..1234
N-1 [E218] COMMUNICATION ABNORMALITY…..1235
TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)…..1237
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER SYSTEM…..1238
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…..1239
JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS…..1243
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM…..1245
E-1 ABNORMALITY IN ENGINE THROTTLE, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)…..1247
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED…..1248
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED…..1249
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED…..1250
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED…..1251
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED…..1252
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED…..1253
E-8 ENGINE DOES NOT START…..1254
E-9 ENGINE SPEED IS IRREGULAR…..1256
a) IDLING SPEED IS IRREGULAR…..1256
b) THERE IS HUNTING…..1258
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)…..1260
E-11 ENGINE DOES NOT STOP…..1262
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)…..1264
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…..1266
METHOD OF USING TROUBLESHOOTING CHARTS…..1267
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..1271
S-2 ENGINE DOES NOT START…..1272
(1) ENGINE DOES NOT TURN…..1272
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…..1273
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…..1274
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…..1275
S-4 ENGINE STOPS DURING OPERATIONS…..1276
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…..1277
S-6 ENGINE LACKS OUTPUT (NO POWER)…..1278
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…..1279
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..1280
S-9 OIL BECOMES CONTAMINATED QUICKLY…..1281
S-10 FUEL CONSUMPTION IS EXCESSIVE…..1282
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…..1283
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..1284
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…..1285
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..1286
S-15 ABNORMAL NOISE IS MADE…..1287
S-16 VIBRATION IS EXCESSIVE…..1288
TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)…..1289
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…..1290
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…..1291
JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS…..1299
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE…..1301
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)…..1303
C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED…..1304
C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED…..1306
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED…..1308
C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED…..1310
C-6 [E207] SHORT CIRCUIT IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED…..1312
C-7 [E208] DISCONNECTION IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED…..1313
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…..1314
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…..1316
C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED…..1318
C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED…..1319
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED…..1320
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED…..1321
C-14 [E231] SHORT CIRCUIT IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED…..1322
C-15 [E235] DISCONNECTION IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED…..1323
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED…..1324
C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…..1326
C-18 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…..1327
C-19 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…..1328
C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…..1329
C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED…..1330
C-22 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED…..1331
C-23 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)…..1332
TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)…..1334
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE…..1335
F-1 BIT PATTERN 20-(1) (SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP…..1337
F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP…..1338
F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP…..1339
F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP…..1340
F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP…..1341
F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP…..1342
F-7 BIT PATTERN 21-(1) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP…..1343
F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP…..1344
F-9 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP…..1345
F-10 BIT PATTERN 22-(5) (KEROSENE MODE CONNECTION) DOES NOT LIGHT UP…..1346
F-11 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP…..1347
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…..1348
PUMP MERGE/DIVIDER LOGIC, SOLENOID ACTUATION TABLE…..1350
TABLE OF FAILURE MODES AND CAUSES…..1351
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…..1355
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…..1357
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…..1358
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…..1358
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)…..1359
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…..1359
H-7 BOOM IS SLOW OR LACKS POWER…..1360
H-8 ARM IS SLOW OR LACKS POWER…..1362
H-9 BUCKET IS SLOW OR LACKS POWER…..1364
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET)DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)…..1365
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)…..1365
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…..1366
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED…..1366
H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED…..1367
H-15 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION…..1367
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…..1367
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW…..1368
H-18 IN SWING + ARM, ARM IS SLOW…..1368
H-19 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY…..1368
H-20 TRAVEL DEVIATION…..1369
a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL…..1369
b) EXCESSIVE TRAVEL DEVIATION WHEN STARTING…..1369
H-21 TRAVEL SPEED IS SLOW…..1370
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER…..1372
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED…..1374
H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…..1374
H-25 DOES NOT SWING…..1375
a) DOES NOT SWING TO EITHER LEFT OR RIGHT…..1375
b) DOES NOT SWING IN ONE DIRECTION…..1375
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW…..1376
a) SWING ACCELERATION IS POOR…..1376
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING…..1378
a) ONE DIRECTION ONLY…..1378
b) BOTH DIRECTIONS…..1378
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…..1379
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…..1379
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING…..1380
a) WHEN SWING HOLDING BRAKE IS RELEASED…..1380
b) WHEN SWING HOLDING BRAKE IS APPLIED…..1380
H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED…..1381
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…..1382
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…..1384
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM…..1386
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED, E[102] ERROR IN CLOCK DATA IS DISPLAYED…..1390
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED…..1391
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED…..1392
M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED…..1392
M-5 [E108] ENGINE WATER TEMPERATURE 105℃ DETECTED IS DISPLAYED…..1393
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS…..1394
a) NONE OF LAMPS ON MONITOR PANEL LIGHT UP…..1394
b) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP…..1394
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT…..1396
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)…..1396
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH…..1397
a) (COOLANT LEVEL) FLASHES…..1397
b) (ENGINE OIL LEVEL) FLASHES…..1398
c) (HYDRAULIC OIL LEVEL) FLASHES…..1399
M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP…..1400
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH…..1401
a) ALTERNATOR SYSTEM…..1401
b) ENGINE OIL PRESSURE SYSTEM…..1402
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH…..1403
a) ALTERNATOR SYSTEM…..1403
b) ENGINE OIL PRESSURE SENSOR SYSTEM…..1404
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH…..1405
a) (ENGINE OIL PRESSURE) FLASHES…..1405
b) (COOLANT LEVEL) FLASHES…..1405
c) (BATTERY CHARGE) FLASHES…..1405
d) (COOLANT TEMPERATURE) FLASHES…..1406
e) (FUEL LEVEL) FLASHES…..1406
f) (AIR CLEANER CLOGGING) FLASHES …..1407
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…..1408
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS…..1408
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…..1409
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE…..1410
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY…..1410
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL…..1411
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY…..1411
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP…..1412
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH…..1412
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING…..1413
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED…..1413
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM…..1414
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM…..1415
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM…..1416
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM…..1417
M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM…..1418
M-30 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113)…..1419
a) WIPER DOES NOT WORK…..1419
b) WIPER SWITCH IS NOT BEING OPERATED BUT WIPER IS ACTUATED…..1424
M-31 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114)…..1425
a) WASHER MOTOR DOES NOT WORK…..1425
b) SWITCH IS NOT BEING OPERATED BUT WASHER IS ACTUATED…..1426
M-32 ELECTRIC GREASE GUN DOES NOT WORK…..1428
30 DISASSEMBLY AND ASSEMBLY…..1429
METHOD OF USING MANUAL…..1431
PRECAUTIONS WHEN CARRYING OUT OPERATION…..1433
SPECIAL TOOL LIST…..1435
SKETCHES OF SPECIAL TOOLS…..1441
STARTING MOTOR ASSEMBLY…..1449
REMOVAL AND INSTALLATION…..1449
ALTERNATOR ASSEMBLY…..1450
REMOVAL AND INSTALLATION…..1450
ENGINE OIL COOLER ASSEMBLY…..1451
REMOVAL AND INSTALLATION…..1451
FUEL INJECTION PUMP ASSEMBLY…..1452
REMOVAL…..1452
INSTALLATION…..1454
WATER PUMP ASSEMBLY…..1455
REMOVAL AND INSTALLATION…..1455
NOZZLE HOLDER ASSEMBLY…..1456
REMOVAL AND INSTALLATION…..1456
TURBOCHARGER ASSEMBLY…..1457
REMOVAL AND INSTALLATION…..1457
THERMOSTAT ASSEMBLY…..1458
REMOVAL AND INSTALLATION…..1458
ENGINE FRONT SEAL…..1459
REMOVAL AND INSTALLATION…..1459
ENGINE REAR SEAL…..1460
REMOVAL…..1460
INSTALLATION…..1461
CYLINDER HEAD ASSEMBLY…..1464
REMOVAL…..1464
INSTALLATION…..1468
GOVERNOR MOTOR ASSEMBLY…..1471
REMOVAL…..1471
INSTALLATION…..1471
AFTERCOOLER CORE ASSEMBLY…..1472
REMOVAL AND INSTALLATION…..1472
HYDRAULIC COOLER ASSEMBLY…..1473
REMOVAL…..1473
INSTALLATION…..1474
RADIATOR, HYDRAULIC COOLER ASSEMBLY…..1475
REMOVAL…..1475
INSTALLATION…..1477
ENGINE, MAIN PUMP ASSEMBLY…..1478
REMOVAL…..1478
INSTALLATION…..1481
DAMPER ASSEMBLY…..1482
REMOVAL AND INSTALLATION…..1482
FUEL TANK ASSEMBLY…..1483
REMOVAL AND INSTALLATION…..1483
CENTER SWIVEL JOINT ASSEMBLY…..1484
REMOVAL AND INSTALLATION…..1484
DISASSEMBLY AND ASSEMBLY…..1486
FINAL DRIVE ASSEMBLY…..1488
REMOVAL AND INSTALLATION…..1488
DISASSEMBLY…..1489
ASSEMBLY…..1493
TRAVEL MOTOR ASSEMBLY…..1499
DISASSEMBLY…..1499
ASSEMBLY…..1504
SPROCKET…..1515
REMOVAL AND INSTALLATION…..1515
SWING MOTOR ASSEMBLY…..1516
REMOVAL AND INSTALLATION…..1516
DISASSEMBLY…..1517
ASSEMBLY…..1520
SWING MACHINERY ASSEMBLY…..1527
REMOVAL AND INSTALLATION…..1527
DISASSEMBLY…..1528
ASSEMBLY…..1532
REVOLVING FRAME ASSEMBLY…..1537
REMOVAL…..1537
INSTALLATION…..1538
SWING CIRCLE ASSEMBLY…..1539
REMOVAL AND INSTALLATION…..1539
IDLER, RECOIL SPRING ASSEMBLY…..1540
REMOVAL AND INSTALLATION…..1540
IDLER ASSEMBLY…..1541
DISASSEMBLY…..1541
ASSEMBLY…..1542
RECOIL SPRING ASSEMBLY…..1544
DISASSEMBLY…..1544
ASSEMBLY…..1545
TRACK ROLLER ASSEMBLY…..1546
REMOVAL AND INSTALLATION…..1546
DISASSEMBLY…..1547
ASSEMBLY…..1548
CARRIER ROLLER ASSEMBLY…..1550
REMOVAL AND INSTALLATION…..1550
DISASSEMBLY…..1551
ASSEMBLY…..1553
TRACK SHOE ASSEMBLY…..1555
REMOVAL AND INSTALLATION…..1555
HYDRAULIC TANK ASSEMBLY…..1556
REMOVAL…..1556
INSTALLATION…..1557
MAIN PUMP ASSEMBLY…..1558
REMOVAL…..1558
INSTALLATION…..1559
DISASSEMBLY…..1560
ASSEMBLY…..1566
MAIN PUMP INPUT SHAFT OIL SEAL…..1581
REMOVAL AND INSTALLATION…..1581
CONTROL VALVE ASSEMBLY…..1582
REMOVAL…..1582
INSTALLATION…..1584
DISASSEMBLY…..1585
ASSEMBLY…..1591
PUMP MERGE/DIVIDER VALVE ASSEMBLY…..1598
DISASSEMBLY AND ASSEMBLY…..1598
PRESSURE COMPENSATION VALVE ASSEMBLY…..1599
DISASSEMBLY AND ASSEMBLY…..1599
SERVO VALVE ASSEMBLY FOR FRONT PUMP…..1600
REMOVAL AND INSTALLATION…..1600
SERVO VALVE ASSEMBLY FOR REAR PUMP…..1601
REMOVAL AND INSTALLATION…..1601
LS-EPC SOLENOID VALVE ASSEMBLY…..1602
REMOVAL AND INSTALLATION…..1602
SOLENOID VALVE ASSEMBLY…..1603
REMOVAL AND INSTALLATION…..1603
WORK EQUIPMENT PPC VALVE ASSEMBLY…..1604
REMOVAL AND INSTALLATION…..1604
DISASSEMBLY…..1605
ASSEMBLY…..1606
TRAVEL PPC VALVE ASSEMBLY…..1607
REMOVAL AND INSTALLATION…..1607
DISASSEMBLY…..1608
ASSEMBLY…..1609
PPC SHUTTLE VALVE ASSEMBLY…..1610
REMOVAL…..1610
INSTALLATION…..1611
DISASSEMBLY…..1612
ASSEMBLY…..1613
BOOM LOCK VALVE ASSEMBLY…..1614
REMOVAL AND INSTALLATION…..1614
DISASSEMBLY AND ASSEMBLY…..1615
BOOM CYLINDER ASSEMBLY…..1616
REMOVAL…..1616
INSTALLATION…..1617
ARM CYLINDER ASSEMBLY…..1618
REMOVAL…..1618
INSTALLATION…..1619
BUCKET CYLINDER ASSEMBLY…..1620
REMOVAL…..1620
INSTALLATION…..1621
HYDRAULIC CYLINDER ASSEMBLY…..1622
DISASSEMBLY…..1622
ASSEMBLY…..1625
WORK EQUIPMENT ASSEMBLY…..1629
REMOVAL…..1629
INSTALLATION…..1630
BUCKET ASSEMBLY…..1631
REMOVAL…..1631
INSTALLATION…..1632
ARM ASSEMBLY…..1633
REMOVAL…..1633
INSTALLATION…..1634
BUCKET, ARM ASSEMBLY…..1635
REMOVAL…..1635
INSTALLATION…..1636
BOOM ASSEMBLY…..1637
REMOVAL…..1637
INSTALLATION…..1638
OPERATOR'S CAB ASSEMBLY…..1639
REMOVAL…..1639
INSTALLATION…..1640
COUNTERWEIGHT ASSEMBLY…..1641
REMOVAL AND INSTALLATION…..1641
AIR CONDITIONER COMPRESSOR ASSEMBLY…..1642
REMOVAL AND INSTALLATION…..1642
CONDENSER ASSEMBLY…..1643
REMOVAL AND INSTALLATION…..1643
RECEIVER TANK ASSEMBLY…..1644
REMOVAL AND INSTALLATION…..1644
AIR CONDITIONER UNIT ASSEMBLY…..1645
REMOVAL…..1645
INSTALLATION…..1646
GOVERNOR, PUMP CONTROLLER ASSEMBLY…..1647
REMOVAL AND INSTALLATION…..1647
MONITOR PANEL ASSEMBLY…..1648
REMOVAL AND INSTALLATION…..1648
CONTROL STAND CASE…..1649
REMOVAL…..1649
INSTALLATION…..1650
40 MAINTENANCE STANDARD…..1651
ENGINE MOUNT…..1652
SWING MACHINERY…..1653
SWING CIRCLE…..1655
FINAL DRIVE…..1657
SPROCKET…..1659
TRACK FRAME AND RECOIL SPRING…..1661
IDLER…..1662
CARRIER ROLLER…..1664
TRACK ROLLER…..1665
TRACK SHOE…..1666
HYDRAULIC PUMP…..1670
CONTROL VALVE…..1671
SELF-REDUCING PRESSURE VALVE…..1678
SUCTION-SAFETY VALVE…..1679
SWING MOTOR…..1680
TRAVEL MOTOR…..1681
WORK EQUIPMENT・SWING PPC VALVE…..1682
TRAVEL PPC VALVE …..1683
SERVICE PPC VALVE…..1684
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE…..1685
LS-EPC VALVE…..1686
SOLENOID VALVE…..1687
CENTER SWIVEL JOINT…..1688
BOOM HOLDING VALVE…..1690
HYDRAULIC CYLINDER…..1691
WORK EQUIPMENT…..1694
DIMENSIONS OF WORK EQUIPMENT…..1698
90 OTHERS…..1702
HYDRAULIC CIRCUIT DIAGRAM …..1703
BACK HOE…..1703
LOADING SHOVEL…..1704
ELECTRIC CIRCUIT DIAGRAM …..1705
BACK HOE…..1705
ELECTRIC CIRCUIT DIAGRAM (1/3) WITH POWER WINDOW…..1705
ELECTRIC CIRCUIT DIAGRAM (2/3) WITH POWER WINDOW…..1706
ELECTRIC CIRCUIT DIAGRAM (3/3) WITH POWER WINDOW…..1707
ELECTRIC CIRCUIT DIAGRAM (1/3) PC400-6 SERIAL NO.: 32250 AND UP PC450-6 SERIAL NO.: 12144 AND UP WITHOUT POWER WINDOW …..1708
ELECTRIC CIRCUIT DIAGRAM (2/3) PC400-6 SERIAL NO.: 32250 AND UP PC450-6 SERIAL NO.: 12144 AND UP WITHOUT POWER WINDOW…..1709
ELECTRIC CIRCUIT DIAGRAM (3/3) PC400-6 SERIAL NO.: 32250 AND UP PC450-6 SERIAL NO.: 12144 AND UP WITHOUT POWER WINDOW…..1710
LOADING SHOVEL…..1711
ELECTRIC CIRCUIT DIAGRAM (1/3)…..1711
ELECTRIC CIRCUIT DIAGRAM (2/3)…..1712
ELECTRIC CIRCUIT DIAGRAM (1/3)…..1713
SEBM023600 – Hydraulic Excavator PC400-6, PC400LC-6, PC450-6, PC450LC-6 Shop Manual Supplement…..1714
COVER…..1714
CONTENTS…..1715
GENERAL…..1717
SPECIFICATIONS…..1717
WEIGHT TABLE…..1721
STRUCTURE AND FUNCTION…..1725
RADIATOR, OIL COOLER…..1725
POWER TRAIN…..1726
TESTING AND ADJUSTING…..1727
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…..1727
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…..1728
MEASURING EXHAUST COLOR…..1737
TESTING AND ADJUSTING FUEL INJECTION TIMING…..1738
MEASURING AIR SUPPLY PRESSURE (BOOST PRESURE)…..1741
DISASSEMBLY AND ASSEMBLY…..1743
TURBOCHARGER ASSEMBLY…..1743
CYLINDER HEAD ASSEMBLY…..1744
AFTERCOOLER ASSEMBLY…..1746
HYDRAULIC COOLER ASSEMBLY…..1747
RADIATOR, HYDRAULIC COOLER ASSEMBLY…..1749
SEBM033000 – Hydraulic Excavator PC400-7, PC400LC-7, PC450-7, PC450LC-7 Shop Manual…..1752
CONTENTS…..1753
No. of page…..1753
01 GENERAL…..1754
SPECIFICATION DRAWINGS 01- 2…..1754
SPECIFICATIONS 01- 4…..1754
WEIGHT TABLE 01- 8…..1754
FUEL, COOLANT AND LUBRICANTS 01- 12…..1754
SPECIFICATION DRAWINGS…..1755
SPECIFICATIONS…..1757
PC400-7, PC400LC-7…..1757
: The “Mi” mode is on the multi-monitor specification machine only…..1757
PC450-7, PC450LC-7…..1759
: The “Mi” mode is on the multi-monitor specification machine only…..1759
WEIGHT TABLE…..1761
PC400-7, PC400LC-7…..1761
k This weight table is for use when handling components or when transporting the machine…..1761
Unit: kg…..1761
PC450-7, PC450LC-7…..1763
Unit: kg…..1763
FUEL, COOLANT AND LUBRICANTS…..1765
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…..1766
ENGINE RELATED PARTS…..1767
1. Drive plate…..1767
2. Torsion spring…..1767
3. Stopper pin…..1767
4. Friction plate…..1767
5. Damper assembly…..1767
6. Muffler…..1767
7. Rear engine mount…..1767
8. Front engine mount…..1767
RADIATOR • OIL COOLER • AFTERCOOLER…..1768
1. Oil cooler…..1768
2. Radiator…..1768
3. Radiator cap…..1768
4. Reservoir tank…..1768
5. Net…..1768
6. Shroud…..1768
7. Radiator inlet hose…..1768
8. Radiator outlet hose…..1768
9. Aftercooler…..1768
10. Condenser…..1768
11. Fuel cooler…..1768
POWER TRAIN…..1769
1. Idler…..1769
2. Center swivel joint…..1769
3. Control valve…..1769
4. Final drive…..1769
5. Travel motor (KMV 200ADT-2)…..1769
6. Engine (SAA6D125-3E)…..1769
7. Hydraulic pump (HPV190+190)…..1769
8. Travel speed solenoid valve…..1769
9. Swing brake solenoid valve…..1769
10. Swing machinery…..1769
11. Swing motor (KMF230ABE-5)…..1769
12. Swing circle…..1769
FINAL DRIVE…..1771
1. Level plug…..1772
2. Drain plug…..1772
3. No. 1 planetary gear (No. of teeth: 43)…..1772
4. No. 1 sun gear (No. of teeth: 10)…..1772
5. No. 2 sun gear (No. of teeth: 18)…..1772
6. No. 1 planetary carrier…..1772
7. No. 2 planetary carrier…..1772
8. Cover…..1772
9. Ring gear (No. of teeth: 98)…..1772
10. Sprocket…..1772
11. Floating seal…..1772
12. Travel motor…..1772
13. No. 2 planetary gear (No. of teeth: 38)…..1772
SWING MACHINERY…..1773
1. Swing pinion (No. of teeth: 13)…..1774
2. Cover…..1774
3. Case…..1774
4. No. 2 planetary gear…..1774
5. No. 2 sun gear…..1774
6. Ring gear…..1774
7. No. 1 sun gear…..1774
8. Swing motor…..1774
9. Oil level gauge…..1774
10. No. 1 planetary gear…..1774
11. No. 1 planetary carrier…..1774
12. No. 2 planetary carrier…..1774
13. Drain plug…..1774
SWING CIRCLE…..1775
1. Swing circle inner race (No. of teeth: 84)…..1775
2. Ball…..1775
3. Swing circle outer race…..1775
a. Inner race soft zone “S” position…..1775
b. Outer race soft zone “S” position…..1775
TRACK FRAME AND RECOIL SPRING…..1777
1. Idler…..1777
2. Track frame…..1777
3. Carrier roller…..1777
4. Final drive…..1777
5. Track roller…..1777
6. Track shoe…..1777
7. Center guard…..1777
8. Recoil spring…..1777
9. Front guard…..1777
IDLER…..1779
CARRIER ROLLER…..1781
TRACK ROLLER…..1782
TRACK SHOE…..1783
TRACK SHOE…..1783
TRIPLE GROUSER SHOE…..1786
HYDRAULIC PIPING DRAWING…..1787
1. Bucket cylinder…..1787
2. Arm cylinder…..1787
3. Boom cylinder…..1787
4. Swing motor…..1787
5. Control valve…..1787
6. Oil cooler…..1787
7. Hydraulic filter…..1787
8. Hydraulic pump…..1787
9. L.H. travel motor…..1787
10. Hydraulic tank…..1787
11. Multi-pattern selector valve…..1787
12. L.H. PPC valve…..1787
13. Safety lever (electric type)…..1787
14. Center swivel joint…..1787
15. R.H. PPC valve…..1787
16. Travel PPC valve…..1787
17. Attachment circuit selector valve…..1787
18. Holding valve…..1787
19. Accumulator…..1787
20. Solenoid valve assembly…..1787
HYDRAULIC TANK…..1789
1. Oil filler cap…..1789
2. Breather…..1789
3. Hydraulic tank…..1789
4. Sight gauge…..1789
5. Strainer…..1789
6. Filter element…..1789
7. Strainer…..1789
8. Bypass valve…..1789
HYDRAULIC PUMP…..1791
1. Front main pump…..1791
2. Rear main pump…..1791
3. LS valve…..1791
4. PC valve…..1791
5. LS-EPC valve…..1791
6. PC-EPC valve…..1791
7. Variable volume valve…..1791
1. Shaft (Front)…..1792
2. Cradle…..1792
3. Case (Front)…..1792
4. Rocker cam…..1792
5. Shoe…..1792
6. Piston…..1792
7. Cylinder block…..1792
8. Valve plate…..1792
9. End cap…..1792
10. Shaft (Rear)…..1792
11. Case (Rear)…..1792
12. Servo piston…..1792
1) Operation of pump…..1794
i Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When……1794
ii Center line X of rocker cam (4) maintains swash plate angle in relation to the axial direction……1794
iii If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) ……1794
2) Control of discharge amount…..1795
1. Plug…..1796
2. Locknut…..1796
3. Sleeve…..1796
4. Spring…..1796
5. Seat…..1796
6. Spool…..1796
7. Piston…..1796
8. Sleeve…..1796
1. Servo piston assembly…..1796
2. Plug…..1796
3. Pin…..1796
4. Spool…..1796
5. Retainer…..1796
6. Seat…..1796
7. Cover…..1796
8. Wiring…..1796
1) When control valve is at neutral position…..1798
2) Operation in increase direction for pump discharge amount…..1799
3) Operation in decrease direction for pump discharge amount…..1800
4) When servo piston is balanced…..1801
1) When pump controller is normal…..1802
a. When the load on the actuator is small and pump pressures PP1 and PP2 are low…..1802
b. When load on actuator is large and pump discharge pressure is high…..1805
2) When pump controller is abnormal and emergency pump drive switch is ON…..1807
a. When load on main pump is light…..1807
b. When main pump load is heavy…..1808
LS(pc)-EPC VALVE…..1809
1. Body…..1809
2. Spool…..1809
3. Spring…..1809
4. Rod…..1809
5. Coil…..1809
6. Plunger…..1809
7. Connector…..1809
1. When signal current is 0 (coil de-energized)…..1810
2. When signal current is very small (coil energized)…..1811
3. When signal current is maximum (coil energized)…..1811
variable volume valve…..1812
1. Block…..1812
2. Plug…..1812
3. Spring…..1812
4. Piston…..1812
CONTROL VALVE…..1815
1. 6-spool valve…..1815
2. Cover 1…..1815
3. Cover 2…..1815
4. Pump merge-divider valve…..1815
5. Back pressure valve…..1815
6. Boom lock valve…..1815
7. Boom, arm Hi valve…..1815
8. Quick return valve…..1815
9. Boom Hi check valve…..1815
1. Unload valve…..1818
2. Pressure compensation valve (Arm OUT)…..1818
3. Pressure compensation valve (Right travel reverse)…..1818
4. Pressure compensation valve (Left swing)…..1818
5. Pressure compensation valve (Boom RAISE)…..1818
6. Pressure compensation valve (Left travel reverse)…..1818
7. Pressure compensation valve (Bucket CURL)…..1818
8. Pressure compensation valve (Boom RAISE)…..1818
9. Pressure compensation valve (Arm IN)…..1818
10. Pressure compensation valve (Bucket DUMP)…..1818
11. Pressure compensation valve (Left travel forward)…..1818
12. Pressure compensation valve (Boom LOWER)…..1818
13. Pressure compensation valve (Right swing)…..1818
14. Pressure compensation valve (Right travel forward)…..1818
15. Pressure compensation valve (Arm IN)…..1818
16. Main relief valve…..1818
1. Spool (Arm)…..1819
2. Spool (Right travel)…..1819
3. Spool (Swing)…..1819
4. Spool (Boom)…..1819
5. Spool (Left travel)…..1819
6. Spool (Bucket)…..1819
7. Spool (Boom Hi)…..1819
8. Spool (Arm Hi)…..1819
9. Unload valve…..1819
10. Main relief valve…..1819
1. Safety-suction valve (Arm OUT)…..1820
2. Suction valve (Right travel reverse)…..1820
3. Suction valve (Boom RAISE)…..1820
4. Suction valve (Left travel reverse)…..1820
5. Safety-suction valve (Boom Hi)…..1820
6. Safety-suction valve (Arm IN)…..1820
7. Safety-suction valve (Bucket DUMP)…..1820
8. Suction valve (Left travel forward)…..1820
9. Safety-suction valve (2-stage) (Boom LOWER)…..1820
10. Suction valve (Right travel forward)…..1820
11. Safety-suction valve (Arm IN)…..1820
12. LS shuttle valve (Arm, right travel)…..1820
13. LS select valve…..1820
14. LS shuttle valve (Boom, left travel, bucket)…..1820
15. LS check valve…..1820
16. Pressure relief plug…..1820
1. Unload valve…..1821
2. Main relief valve…..1821
3. Safety valve (Boom RAISE)…..1821
4. Lift check valve…..1821
5. Safety-suction valve…..1821
6. Spool…..1821
7. Pressure compensation valve (OUT)…..1821
8. LS shuttle valve…..1821
9. Pressure compensation valve (IN)…..1821
10. Safety-suction valve…..1821
11. Check valve for regeneration circuit…..1821
12. Suction valve…..1821
13. Spool…..1821
14. Pressure compensation valve (Reverse)…..1821
15. LS shuttle valve…..1821
16. Pressure compensation valve (Forward)…..1821
17. Suction valve…..1821
1. Spool…..1823
2. Pressure compensation valve (Left)…..1823
3. LS select valve…..1823
4. Pressure compensation valve (Right)…..1823
5. Suction valve…..1823
6. Spool…..1823
7. Pressure compensation valve (RAISE)…..1823
8. Hydraulic drift prevention valve…..1823
9. LS shuttle valve…..1823
10. Pressure compensation valve (Lower)…..1823
11. Safety-suction valve…..1823
12. Check valve for regeneration circuit…..1823
13. Pump merge-divider valve (Travel junction valve)…..1823
14. Return spring…..1823
15. Suction valve…..1823
16. Spool…..1823
17. Pressure compensation valve (Reverse)…..1823
18. LS shuttle valve…..1823
19. Pressure compensation valve (Forward)…..1823
20. Suction valve…..1823
1. Safety-suction valve…..1825
2. Spool…..1825
3. Pressure compensation valve (CURL)…..1825
4. LS shuttle valve…..1825
5. Pressure compensation valve (DUMP)…..1825
6. Safety-suction valve…..1825
7. Boom Hi spool…..1825
8. Pressure compensation valve (Boom RAISE)…..1825
9. Boom Hi check valve…..1825
10. Quick-return valve…..1825
11. Pressure compensation valve (Arm IN)…..1825
12. Arm Hi spool…..1825
13. Safety-suction valve…..1825
1. Unload valve…..1827
2. Main relief valve…..1827
3. Pump merge-divider valve (Main)…..1827
4. Return spring…..1827
5. Pump merge-divider valve (For LS)…..1827
6. Return spring…..1827
7. Valve (Sequence valve)…..1827
8. Spring (Sequence valve)…..1827
9. LS bypass plug…..1827
10. Screw…..1827
11. Poppet…..1827
12. Spring (Pressure reducing valve pilot)…..1827
13. Spring (Pressure reducing valve main)…..1827
14. Valve (Pressure reducing valve)…..1827
15. Spring (Safety valve)…..1827
16. Ball…..1827
MAIN RELIEF VALVE…..1829
1. Spring…..1829
2. Poppet…..1829
1. When pilot pressure P is OFF: Low-pressure setting The set pressure is determined by the insta……1829
2. When pilot pressure P is ON: High-pressure setting In addition to the installed load of spring……1829
CLSS…..1831
OUTLINE OF CLSS…..1831
1) Fine control not influenced by load…..1831
2) Control enabling digging even with fine control…..1831
3) Ease of compound operation ensured by flow divider function using area of opening of spool dur……1831
4) Energy saving using variable pump control…..1831
1) Control of pump swash plate…..1832
2) Pressure compensation…..1833
SELF PRESSURE REDUCING VALVE…..1834
1. When engine is stopped…..1834
2. When in neutral or load pressure P2 is low (When boom is lowered and arm is in IN position and……1835
3. When load pressure P2 is high…..1835
4. When abnormally high pressure is generated…..1836
SWING MOTOR…..1837
1. Brake spring…..1839
2. Drive shaft…..1839
3. Spacer…..1839
4. Case…..1839
5. Disc…..1839
6. Plate…..1839
7. Brake piston…..1839
8. Housing…..1839
9. Piston…..1839
10. Cylinder block…..1839
11. Valve plate…..1839
12. Reverse prevention valve…..1839
13. Center shaft…..1839
14. Center spring…..1839
15. Safety valve…..1839
16. Check valve…..1839
17. Shuttle valve…..1839
RELIEF VALVE…..1841
1. Outline…..1841
2. Function…..1841
3. Operation…..1841
1) When starting swing…..1841
2) When stopping swing…..1841
1. When swing lock solenoid valve is deactivated…..1842
2. When swing lock solenoid valve is excited…..1842
1. Valve body…..1843
2. Spool (MA side)…..1843
3. Spring (MA side)…..1843
4. Plug…..1843
5. Spool (MB side)…..1843
6. Spring (MB side)…..1843
7. Plug…..1843
1. When brake pressure is being generated at port MB…..1844
2. After motor stops…..1844
CENTER SWIVEL JOINT…..1845
1. Cover…..1845
2. Body…..1845
3. Slipper seal…..1845
4. O-ring…..1845
5. Shaft…..1845
TRAVEL MOTOR…..1847
1. Output shaft…..1848
2. Motor case…..1848
3. Piston…..1848
4. Cylinder…..1848
5. Valve plate…..1848
6. End cover…..1848
7. Slow return valve…..1848
8. Regulator piston…..1848
9. Plate…..1848
10. Disc…..1848
11. Check valve spring…..1848
12. Check valve…..1848
13. Counterbalance valve…..1848
14. Spool return spring…..1848
15. Safety valve…..1848
16. Rgegulator valve…..1848
17. Spring…..1848
18. Brake spring…..1848
19. Brake piston…..1848
20. Check valve…..1848
1) At low speed (motor swash plate angle at maximumu)…..1850
2) At high speed (motor swash plate angle at minimum)…..1851
PARKING BRAKE…..1852
1. When starting to travel…..1852
2. When stopping travel…..1853
1) Counterbalance valve, check valve…..1854
2) Safety valve (2-direction operation, 2-stage set safety valve)…..1855
1) When pressure in chamber MB has become high (when rotating clockwise)…..1856
2) When stopping travel (low-pressure setting)…..1856
3) When pressure in chamber MA has become high (when rotating counterclockwise)…..1857
1) When starting travel (high-pressure setting)…..1857
TRAVEL JUNCTION VALVE…..1858
VALVE CONTROL…..1860
1. Travel PPC valve…..1860
2. Service PPC valve…..1860
3. Service pedal…..1860
4. L.H. travel lever…..1860
5. R.H. travel lever…..1860
6. R.H. PPC valve…..1860
7. R.H. work equipment control lever…..1860
8. Solenoid valve…..1860
9. Accumulator…..1860
10. Control valve…..1860
11. Hydraulic pump…..1860
12. Junction box…..1860
13. L.H. work equipment control lever…..1860
14. L.H. PPC valve…..1860
TRAVEL PPC SHUTTLE VALVE…..1861
1. When travel is at neutral…..1861
2. When travel is operated…..1863
WORK EQUIPMENT • SWING PPC VALVE…..1865
1. Spool…..1866
2. Metering spring…..1866
3. Centering spring…..1866
4. Piston…..1866
5. Disc…..1866
6. Nut (For connection of lever)…..1866
7. Joint…..1866
8. Plate…..1866
9. Retainer…..1866
10. Body…..1866
11. Filter…..1866
1) At neutral…..1867
2) During fine control (neutral o fine control)…..1867
3) During fine control (when control lever is returned)…..1868
4) At full stroke…..1868
TRAVEL PPC VALVE…..1869
1. Plate…..1870
2. Body…..1870
3. Piston…..1870
4. Collar…..1870
5. Metering spring…..1870
6. Centering spring…..1870
7. Valve…..1870
8. Damper…..1870
9. Steering signal…..1870
10. Steering signal valve spring…..1870
1. While in NEUTRAL…..1872
2. While travelling straight…..1873
3. When steered or pivot-turned…..1874
4. When pivot-turned…..1875
SERVICE PPC VALVE…..1876
1. Spool…..1876
2. Metering spring…..1876
3. Centering spring…..1876
4. Piston…..1876
5. Lever…..1876
6. Plate…..1876
7. Retainer…..1876
8. Body…..1876
SOLENOID VALVE…..1877
1. PPC lock solenoid valve…..1877
2. Travel junction solenoid valve…..1877
3. Merge-divider solenoid valve…..1877
4. Travel speed solenoid valve…..1877
5. Swing brake solenoid valve…..1877
6. Machine push-up solenoid valve…..1877
8. 2-stage relief solenoid valve…..1877
1. Connector…..1878
2. Moving core…..1878
3. Coil…..1878
4. Spool…..1878
5. Block…..1878
6. Spring…..1878
PPC ACCUMULATOR…..1879
1. Gas plug…..1879
2. Shell…..1879
3. Poppet…..1879
4. Holder…..1879
5. Bladder…..1879
6. Oil port…..1879
return oil filter…..1880
For Breaker…..1880
1. Drain plug…..1880
2. Element…..1880
3. Case…..1880
4. Head cover…..1880
5. Relief valve…..1880
BOOM HYDRAULIC DRIFT PREVENTION VALVE…..1881
1. Boom RAISE…..1881
2. Boom at HOLD…..1883
3. Boom LOWER…..1885
ARM HYDRAULIC DRIFT PREVENTION VALVE…..1886
(If equipped)…..1886
1. Arm DUMP…..1886
2. Arm at HOLD…..1887
3. Arm IN…..1888
4. When abnormally high pressure is generated…..1889
quick return valve…..1890
1. Arm at OUT…..1890
2. Arm at HOLD…..1891
LIFT CHECK VALVE…..1892
1. While engine is stopped…..1892
2. While engine is running…..1892
attachment circuit selector valve…..1893
1. Spool…..1893
2. Spring…..1893
1. When attachment other than breaker is installed…..1894
2. When breaker is installed…..1894
HOLDING VALVE…..1895
1. Pilot spool…..1896
2. Spring (1st stage of spool)…..1896
3. Spring (2nd stage of spool)…..1896
4. Safety valve…..1896
5. Check valve…..1896
6. Spring…..1896
1. When the work equipment is in neutral…..1897
2. When oil is sent from main valve to cylinder…..1898
3. When oil is returned from work equipment cylinder to main valve…..1899
HYDRAULIC CYLINDER…..1901
BOOM CYLINDER…..1901
ARM CYLINDER…..1901
BUCKET CYLINDER…..1901
WORK EQUIPMENT…..1903
1. Dimension of arm…..1905
2. Dimension of bucket…..1907
AIR CONDITIONER…..1909
AIR CONDITIONER PIPING…..1909
1. Hot water pickup piping…..1909
2. Receiver tank…..1909
3. Hot water return piping…..1909
4. Condenser…..1909
5. Air conditioner compressor…..1909
6. Refrigerant piping…..1909
7. Air conditioner unit…..1909
8. Duct…..1909
A. Fresh air…..1909
B. Recirculated air…..1909
C. Hot air/cold air…..1909
ENGINE CONTROL…..1910
1. Operation of system…..1910
2. Components of system…..1911
1. Knob…..1911
2. Dial…..1911
3. Spring…..1911
4. Ball…..1911
5. Potentiometer…..1911
6. Connector…..1911
3. Engine controller…..1912
ELECTRONIC CONTROL SYSTEM…..1916
CONTROL FUNCTIONS…..1916
TOTAL SYSTEM DIAGRAM…..1917
1. Engine and Pump control function…..1919
1) Control method in each mode Mode A, Mode E…..1921
2) Function to control pump during travel…..1923
3) Function to control when emergency pump drive switch is turned ON…..1923
2. Pump/Valve control function…..1924
1) LS control function…..1925
2) Cut-off function…..1925
1) 2-stage relief function…..1925
3. One-touch power maximizing/machine push-up function…..1926
1) One-touch power maximizing function…..1927
2) Machine push-up function…..1927
4. Auto-deceleration function…..1928
5. Auto-warm-up/Overheat prevention function…..1930
1) Auto-warm-up function…..1931
2) Overheat prevention function…..1931
6. Swing control function…..1932
1) Swing lock and swing holding brake functions…..1933
2) Quick hydraulic oil warm-up function when swing lock switch is turned on…..1933
7. Travel control function…..1934
1) Pump control function during travel…..1935
1. Travel speed change function…..1935
i) Manual change with travel speed switch…..1935
ii) Automatic change according to engine speed…..1935
iii) Automatic changes according to pump discharge pressure…..1935
8. ATT flow control, circuit selector function (if equipment)…..1936
1) It throttles the ATT PPC pressure and controls the flow when the pedal is depressed fully…..1936
2) In mode B and the other modes, it switches to ATT single acting (B) or double acting (other mo……1936
9. System component parts…..1937
1) Engine revolution sensor…..1937
1. Sensor…..1937
2. Locknut…..1937
3. Wiring harness…..1937
4. Connector…..1937
2) PPC oil pressure switch…..1938
1. Plug…..1938
2. Switch…..1938
3. Connector…..1938
3) Pump pressure sensor…..1939
1. Sensor…..1939
2. Connector…..1939
Pump controller…..1940
Input and output signals…..1941
MONITOR SYSTEM…..1943
1. Monitor section to output alarms when the machine has troubles…..1943
2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperat……1943
1. Monitor panel…..1944
1. Wiper motor…..1946
2. Preheating monitor…..1946
3. Swing lock monitor…..1946
4. Engine water temperature monitor…..1946
5. Hydraulic oil temperature gauge…..1946
6. Engine water temperature gauge…..1946
7. Working mode monitor…..1946
8. Service monitor…..1946
9. Travel speed monitor…..1946
10. Fuel gauge…..1946
11. Fuel level monitor…..1946
12. Hydraulic oil temperature monitor…..1946
13. Power max. monitor…..1946
14. Auto-deceleration monitor…..1946
15. Radiator water level caution…..1946
16. Battery charge caution…..1946
17. Engine oil pressure caution…..1946
18. Engine oil level caution…..1946
19. Air cleaner clogging…..1946
20. Maintenance time warning caution…..1946
1. Selector switch…..1951
2. Selector switch…..1951
3. Display brightness, contrast adjustment switch…..1951
4. Control switch…..1951
5. Window washer switch…..1951
6. Wiper switch…..1951
7. Maintenance switch…..1951
8. Travel speed selector switch…..1951
9. Auto-deceleration switch…..1951
1. A mode, E mode…..1954
1) Press select switch (1) on the monitor to move to the adjustment screen…..1954
2) Press control switch (2) to select the flow level…..1954
3) After completing the level selection, press input confirmation switch (3)…..1954
2. B mode…..1955
1) Press select switch (1) on the monitor to move to the screen for selecting the 3-stage flow le……1955
2) Press control switch (2), or input [01] – [03] with the numeral 10-key pad to choose one on th……1955
3) After completing the level selection, press input confirmation switch (3)…..1955
4) After the flow level is confirmed, the screen changes to the screen shown in the diagram on th……1955
5) Press control switch (2) and select the flow level…..1955
6) After completing the level selection, press input confirmation switch (3)…..1956
7) Check the set value with the working mode monitor…..1956
MAINTENANCE FUNCTION…..1957
Method of checking status maintenance items…..1958
1. Press maintenance switch (1) and switch to the maintenance list display screen…..1958
2. Press control switch (2), or use the 10-key pad to input the number (01 – 10) of the maintenan……1958
maintenance operation…..1958
1. After completing the selection, press input confirmation switch (3)…..1958
2. Use the maintenance reset screen to check the content, and if there is any problem, press inpu……1958
3. Check the content on the check screen, and if there is no problem, press input confirmation sw……1958
brightness, contrast adjustment function…..1959
Adjustment method…..1959
1. Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen…..1959
2. Press control switch (2), or use the 10-key pad to input the number (00 – 02) to select either……1959
3. Press control switch (2) and adjust the brightness and contrast as desired…..1959
service meter check function…..1960
display lcd check function…..1960
user code display function…..1961
SENSOR…..1963
1. Connector…..1964
2. Bracket…..1964
3. Float…..1964
4. Switch…..1964
1. Plug…..1964
2. Contact ring…..1964
3. Contact…..1964
4. Diaphragm…..1964
5. Spring…..1964
6. Terminal…..1964
1. Thermistor…..1964
2. Body…..1964
3. Tube…..1964
4. Tube…..1964
5. Wire…..1964
6. Connector…..1964
1. Float…..1965
2. Connector…..1965
3. Cover…..1965
4. Variable resistor…..1965
90 OTHERS…..1966
HYDRAULIC CIRCUIT DIAGRAM (1/2) 90- 3…..1966
HYDRAULIC CIRCUIT DIAGRAM (2/2) 90- 5…..1966
ELECTRICAL CIRCUIT DIAGRAM (1/5) 90- 7…..1966
ELECTRICAL CIRCUIT DIAGRAM (2/5) 90- 9…..1966
ELECTRICAL CIRCUIT DIAGRAM (3/5) 90- 11…..1966
ELECTRICAL CIRCUIT DIAGRAM (4/5) 90- 13…..1966
ELECTRICAL CIRCUIT DIAGRAM (5/5) 90- 15…..1966
AIR CONDITIONER ELECTRICAL CIRCUIT 90- 17…..1966
SEBM033007 – Hydraulic Excavator PC400-7, PC400LC-7, PC450-7, PC450LC-7 Shop Manual…..1968
COVER…..1968
CONTENTS…..1969
01 GENERAL…..1995
SPECIFICATION DRAWINGS…..1996
SPECIFICATIONS…..1998
WEIGHT TABLE…..2002
FUEL, COOLANT AND LUBRICANTS…..2006
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…..2007
ENGINE RELATED PARTS…..2008
RADIATOR・OIL COOLER・AFTERCOOLER…..2009
POWER TRAIN…..2010
FINAL DRIVE…..2011
SPROCKET…..2013
SWING MACHINERY…..2015
SWING CIRCLE…..2017
TRACK FRAME AND RECOIL SPRING…..2018
IDLER…..2020
CARRIER ROLLER…..2022
TRACK ROLLER…..2023
TRACK SHOE…..2024
HYDRAULIC PIPING DRAWING…..2028
HYDRAULIC TANK…..2030
HYDRAULIC PUMP…..2031
LS(PC)-EPC VALVE…..2049
VARIABLE VOLUME VALVE…..2052
CONTROL VALVE…..2054
MAIN RELIEF VALVE…..2067
CLSS…..2068
SELF PRESSURE REDUCING VALVE…..2071
SWING MOTOR…..2074
REVERSAL PREVENTION VALVE…..2079
CENTER SWIVEL JOINT…..2081
TRAVEL MOTOR…..2082
TRAVEL JUNCTION VALVE…..2093
VALVE CONTROL…..2095
TRAVEL PPC SHUTTLE VALVE…..2096
WORK EQUIPMENT・SWING PPC VALVE…..2100
TRAVEL PPC VALVE…..2104
SERVICE PPC VALVE…..2111
SOLENOID VALVE…..2112
PPC ACCUMULATOR…..2114
RETURN OIL FILTER…..2115
BOOM HYDRAULIC DRIFT PREVENTION VALVE…..2116
ARM HYDRAULIC DRIFT PREVENTION VALVE…..2121
QUICK RETURN VALVE…..2125
LIFT CHECK VALVE…..2127
ATTACHMENT CIRCUIT SELECTOR VALVE…..2128
HOLDING VALVE…..2130
HYDRAULIC CYLINDER…..2135
WORK EQUIPMENT…..2137
AIR CONDITIONER…..2143
ENGINE CONTROL…..2144
ELECTRONIC CONTROL SYSTEM…..2149
MONITOR SYSTEM…..2176
7-SEGMENT MONITOR SYSTEM…..2196
SENSOR…..2203
20 TESTING AND ADJUSTING…..2206
STANDARD VALUE TABLE FOR ENGINE…..2207
STANDARD VALUE TABLE FOR CHASSIS…..2208
TESTING AND ADJUSTING…..2217
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE…..2218
MEASURING ENGINE SPEED…..2220
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…..2221
MEASURING EXHAUST TEMPERATURE…..2222
MEASURING EXHAUST GAS COLOR…..2223
ADJUSTING VALVE CLEARANCE…..2224
MEASURING COMPRESSION PRESSURE…..2226
MEASURING BLOW-BY PRESSURE…..2228
MEASURING ENGINE OIL PRESSURE…..2229
HANDLING OF FUEL SYSTEM DEVICES…..2230
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…..2230
MEASURING FUEL PRESSURE…..2231
BLEEDING AIR FROM FUEL CIRCUIT…..2232
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE…..2234
ADJUSTING ENGINE SPEED SENSOR…..2235
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION…..2236
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…..2237
MEASURING CLEARANCE OF SWING CIRCLE BEARING…..2238
TESTING AND ADJUSTING TRACK SHOE TENSION…..2239
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…..2240
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT…..2244
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…..2245
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT…..2248
MEASURING SOLENOID VALVE OUTPUT PRESSURE…..2253
MEASURING PPC VALVE OUTPUT PRESSURE…..2256
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…..2258
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT…..2259
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT…..2261
MEASURING OIL LEAKAGE…..2262
BLEEDING AIR FROM EACH PART…..2265
TESTING PROCEDURE OF DIODE…..2268
SPECIAL FUNCTIONS OF MONITOR PANEL…..2269
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL…..2296
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER…..2312
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM…..2313
PM-CLINIC SERVICE…..2315
TROUBLESHOOTING…..2322
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..2323
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..2324
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..2325
CHECKS BEFORE TROUBLESHOOTING…..2333
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING…..2334
CONNECTOR ARRANGEMENT DIAGRAM AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM…..2338
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..2355
T-BRANCH BOX AND T-BRANCH TABLE…..2377
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED…..2380
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..2382
ERROR CODE IN ELECTRICAL SYSTEM [E112](SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)…..2384
ERROR CODE IN ELECTRICAL SYSTEM [E113](SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)…..2386
ERROR CODE IN ELECTRICAL SYSTEM [E114](SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM)…..2388
ERROR CODE IN ELECTRICAL SYSTEM [E115](ABNORMAL WINDSHIELD WIPER MOTION)…..2390
ERROR CODE IN ELECTRICAL SYSTEM [E116](ABNORMALITY IN RETRACTING WINDSHIELD WIPER) …..2392
ERROR CODE IN ELECTRICAL SYSTEM (E117](ENG. CONTROLLER S-NET COMM. ERR.)…..2394
ERROR CODE IN ELECTRICAL SYSTEM (E118](PUMP CONTROLLER S-NET COMM. ERR.)…..2396
ERROR CODE IN ELECTRICAL SYSTEM (E128](MONITOR COMM. ABNORMALITY)…..2398
ERROR CODE IN ELECTRICAL SYSTEM (E201](SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)…..2400
ERROR CODE IN ELECTRICAL SYSTEM [E203](SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)…..2401
ERROR CODE IN ELECTRICAL SYSTEM [E204](SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)…..2403
ERROR CODE IN ELECTRICAL SYSTEM [E205](SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)…..2404
ERROR CODE IN ELECTRICAL SYSTEM [E206](SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID)…..2405
ERROR CODE IN ELECTRICAL SYSTEM [E211](DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)…..2406
ERROR CODE IN ELECTRICAL SYSTEM [E213](DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)…..2407
ERROR CODE IN ELECTRICAL SYSTEM [E214](DISCONNECTION OF MERGE/DIVIDE SOLENOID)…..2409
ERROR CODE IN ELECTRICAL SYSTEM [E215](DISCONNECTION IN 2-STAGE RELIEF SOLENOID)…..2410
ERROR CODE IN ELECTRICAL SYSTEM [E216](DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)…..2411
ERROR CODE IN ELECTRICAL SYSTEM [E217](ABNORMAL INPUT MODEL CODE)…..2412
ERROR CODE IN ELECTRICAL SYSTEM [E218](S-NET COMM. DISC.)…..2414
ERROR CODE IN ELECTRICAL SYSTEM [E222](SHORT-CIRCUITING IN LS-EPC SOLENOID)…..2416
ERROR CODE IN ELECTRICAL SYSTEM [E223](DISCONNECTION IN LS-EPC SOLENOID SYSTEM)…..2417
ERROR CODE IN ELECTRICAL SYSTEM [E224](F PUMP P. SENSOR ABNORMALITY)…..2418
ERROR CODE IN ELECTRICAL SYSTEM [E225](R PUMP P. SENSOR ABNORMALITY)…..2420
ERROR CODE IN ELECTRICAL SYSTEM [E226](P. SENSOR POWER ABNORMALITY)…..2422
ERROR CODE IN ELECTRICAL SYSTEM [E227](ABNORMALITY IN ENGINE ROTATION SENSOR) …..2424
ERROR CODE IN ELECTRICAL SYSTEM [E228](SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)…..2425
ERROR CODE IN ELECTRICAL SYSTEM [E232](SHORT-CIRCUITING IN PC-EPC SOLENOID)…..2426
ERROR CODE IN ELECTRICAL SYSTEM [E233](DISCONNECTION IN PC-EPC SOLENOID SYSTEM)…..2428
ERROR CODE IN ELECTRICAL SYSTEM [E238](DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY)…..2430
ERROR CODE IN ELECTRICAL SYSTEM [E245](SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)…..2432
ERROR CODE IN ELECTRICAL SYSTEM [E246](DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)…..2433
ERROR CODE IN ELECTRICAL SYSTEM [E247](ARM IN PPC PRESSURE SENSOR ABNORMALITY)…..2434
ERROR CODE IN ELECTRICAL SYSTEM [E248](BUCKET CURL PPC PRESSURE SENSOR ABNORMALITY)…..2436
ERROR CODE IN ELECTRICAL SYSTEM [E257](PUMP ABNORMALITY)…..2438
ERROR CODE IN ELECTRICAL SYSTEM [E315](BATTERY RELAY DRIVE S/C)…..2440
ERROR CODE IN ELECTRICAL SYSTEM [E91B](ENGINE NE SENSOR PROBLEM)…..2442
ERROR CODE IN ELECTRICAL SYSTEM [E91C](ENGINE G SENSOR PROBLEM)…..2443
ERROR CODE IN ELECTRICAL SYSTEM [E920](ENGINE TYPE SELECTION ERROR)…..2444
ERROR CODE IN ELECTRICAL SYSTEM [E921](ENGINE TYPE MISMATCH)…..2446
ERROR CODE IN ELECTRICAL SYSTEM [E931](FUEL DIAL SYS. ERROR)…..2447
ERROR CODE IN ELECTRICAL SYSTEM [E934](ENGINE COOLANT SENSOR HI ERROR)…..2449
ERROR CODE IN ELECTRICAL SYSTEM [E936](ENGINE OIL PRESS. SW. ERROR)…..2451
ERROR CODE IN ELECTRICAL SYSTEM [E93C](ENGINE BOOST SENSOR ERROR)…..2453
ERROR CODE IN ELECTRICAL SYSTEM [E93D](ENGINE FUEL TEMP. SENSOR ERROR)…..2455
ERROR CODE IN ELECTRICAL SYSTEM [E953](ENGINE COMM. ABNORMALITY)…..2457
ERROR CODE IN ELECTRICAL SYSTEM [E954](SHORT ENGINE STARTER SW.)…..2459
ERROR CODE IN ELECTRICAL SYSTEM [E955](ENGINE S-NET ERROR)…..2461
ERROR CODE IN ELECTRICAL SYSTEM [E956](ENGINE POWER FAILURE (1))…..2463
ERROR CODE IN ELECTRICAL SYSTEM [E957](ENGINE POWER FAILURE (2))…..2465
ERROR CODE IN ELECTRICAL SYSTEM [E95A](ENGINE Q-ADJ. SW. SIGNAL ERROR)…..2467
ERROR CODE IN ELECTRICAL SYSTEM [E96A](ENGINE COOLANT SENSOR LO ERROR)…..2468
ERROR CODE IN ELECTRICAL SYSTEM [E970](PCV1 OVER CURRENT)…..2470
ERROR CODE IN ELECTRICAL SYSTEM [E971](PCV2 OVER CURRENT)…..2471
ERROR CODE IN ELECTRICAL SYSTEM [E974](PCV1 LINE CUT)…..2472
ERROR CODE IN ELECTRICAL SYSTEM [E975](PCV2 LINE CUT)…..2473
ERROR CODE IN ELECTRICAL SYSTEM [E977](RAIL PRESS. SENSOR ERROR)…..2474
ERROR CODE IN ELECTRICAL SYSTEM [E979](RAIL PRESS. HIGH)…..2476
ERROR CODE IN ELECTRICAL SYSTEM [E97A](RAIL PRESS. ABNORMAL)…..2476
ERROR CODE IN ELECTRICAL SYSTEM [E97B](RAIL PRESS. LOW)…..2477
ERROR CODE IN ELECTRICAL SYSTEM [E97C](RAIL PRESS. TOO LOW)…..2479
ERROR CODE IN ELECTRICAL SYSTEM [E97D](RAIL PRESS. CUT OF CONTROL)…..2479
ERROR CODE IN ELECTRICAL SYSTEM [E980](ENG. CONTROLLER ABNORMALITY)…..2480
ERROR CODE IN ELECTRICAL SYSTEM [E981](FUEL INJECTOR 1 DISC.)…..2482
ERROR CODE IN ELECTRICAL SYSTEM [E982](FUEL INJECTOR 2 DISC.)…..2483
ERROR CODE IN ELECTRICAL SYSTEM [E983](FUEL INJECTOR 3 DISC.)…..2484
ERROR CODE IN ELECTRICAL SYSTEM [E984](FUEL INJECTOR 4 DISC.)…..2485
ERROR CODE IN ELECTRICAL SYSTEM [E985](FUEL INJECTOR 5 DISC.)…..2486
ERROR CODE IN ELECTRICAL SYSTEM [E986](FUEL INJECTOR 6 DISC.)…..2487
ERROR CODE IN ELECTRICAL SYSTEM [E98A](FUEL INJECTOR 1-3 S/C)…..2488
ERROR CODE IN ELECTRICAL SYSTEM [E98B](FUEL INJECTOR 4-6 S/C)…..2490
ERROR CODE IN MECHANICAL SYSTEM [A000N1](ENGINE HIGH-IDLING SPEED OUT OF STANDARD)…..2492
ERROR CODE IN MECHANICAL SYSTEM [A000N2](ENGINE LOW-IDLING SPEED OUT OF STANDARD)…..2492
FAILURE CODE IN MECHANICAL SYSTEM [AA10NX](AIRCLEANER CLOGGING…..2493
FAILURE CODE IN MECHANICAL SYSTEM [AB00KE](CHARGE VOLTAGE LOW)…..2495
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG](ENG. OIL PRESS. LOW)…..2497
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK](ENG. OIL LEVEL LOW)…..2499
FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS](ENG. WATER OVERHEAT)…..2500
FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK](ENG. WATER LVL LOW)…..2501
FAILURE CODE IN MECHANICAL SYSTEM [B@HANS](HYDR. OIL OVERHEAT)…..2502
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…..2503
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..2505
E-1 ENGINE DOES NOT START(THE ENGINE DOES NOT ROTATE)…..2506
E-2 PREHEATER DOES NOT OPERATE…..2509
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK…..2511
E-4 AUTO-DECELERATOR DOES NOT OPERATE…..2512
E-5 ALL WORK EQUIPMENT,SWING AND TRAVEL DO NOT MOVE…..2513
E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE…..2515
E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY…..2516
E-8 ATTACHMENT CIRCUIT DOES NOT CHANGE…..2518
E-9 NO DISPLAY IN MONITOR PANEL AT ALL…..2520
E-10 PART OF DISPLAY ON MONITOR PANEL IS MISSING…..2521
E-11 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL…..2521
E-12 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING…..2522
E-13 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY…..2523
E-14 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY…..2525
E-15 FUEL GAUGE DOES NOT DISPLAY CORRECTLY…..2526
E-16 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY…..2527
E-17 WHEN MONITOR SWITCH IS OPERATED,NOTHING IS DISPLAYED…..2529
E-18 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK…..2531
E-19 ALARM BUZZER CANNOT BE CANCELLED…..2535
E-20 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..2536
E-21 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..2537
E-22 "ARM IN" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION…..2538
E-23 "ARM DUMPING " IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..2539
E-24 "BUCKET CURL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION…..2540
E-25 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..2541
E-26 "SWING" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION…..2542
E-27 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..2544
E-28 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..2546
E-29 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..2548
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING…..2550
E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM…..2552
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H MODE)…..2563
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM…..2564
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..2566
H-1 ALL WORK EQUIPMENT LACK POWER,OR TRAVEL AND SWING SPEEDS ARE SLOW…..2567
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS…..2568
H-3 NO WORK EQUIPMENT,TRAVEL OR SWING MOVE…..2569
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP…..2569
H-5 AUTO-DECELERATOR DOES NOT WORK…..2570
H-6 FINE CONTROL MODE DOES NOT FUNCTION…..2570
H-7 BOOM MOVES SLOWLY OR LACKS POWER…..2571
H-8 ARM MOVES SLOWLY OR LACKS POWER…..2572
H-9 BUCKET MOVES SLOWLY OR LACKS POWER…..2573
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION…..2573
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT…..2574
H-12 WORK EQUIPMENT HAS BIG TIME LAG…..2575
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT…..2575
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK…..2575
H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK…..2576
H-16 IN COMPOUND OPERATION,WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY…..2577
H-17 IN SWING + BOOM RAISE OPERATION,BOOM MOVES SLOWLY…..2577
H-18 IN SWING + TRAVEL,TRAVEL SPEED DROPS SHARPLY…..2577
H-19 MACHINE SWERVES IN TRAVEL…..2578
H-20 MACHINE TRAVELS SLOWLY…..2579
H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER…..2580
H-22 TRAVEL SPEED DOES NOT SHIFT,OR IT IS SLOWER OR FASTER THAN PRESET SPEED…..2581
H-23 TRACK SHOE DOES NOT TURN(ON ONE SIDE ONLY)…..2582
H-24 MACHINE DOES NOT SWING…..2583
H-25 SWING ACCELERATION IS POOR,OR SWING SPEED IS SLOW…..2584
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING…..2585
H-27 THERE IS BIG SHOCK WHEN STOPPING SWING…..2586
H-28 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING…..2586
H-29 SWING NATURAL DRIFT IS TOO BIG…..2587
H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE…..2588
H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED…..2588
TROUBLESHOOTING OF ENGINE (S MODE)…..2589
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..2590
METHOD OF USING TROUBLESHOOTING CHARTS…..2591
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..2594
S-2 ENGINE DOES NOT START…..2595
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)…..2598
S-4 ENGINE STOPS DURING OPERATIONS…..2599
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)…..2600
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…..2601
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)…..2602
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..2603
S-9 OIL BECOMES CONTAMINATED QUICKLY…..2604
S-10 FUEL CONSUMPTION IS EXCESSIVE…..2605
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)…..2606
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..2607
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)…..2608
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)…..2609
S-15 ABNORMAL NOISE IS MADE…..2610
S-16 VIBRATION IS EXCESSIVE…..2611
30 DISASSEMBLY AND ASSEMBLY…..2612
HOW TO READ THIS MANUAL…..2613
PRECAUTIONS WHEN PERFORMING OPERATION…..2615
SPECIAL TOOL LIST…..2617
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…..2625
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…..2632
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…..2636
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…..2639
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY…..2642
REMOVAL AND INSTALLATION OF NOZZLE TIP…..2645
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY…..2647
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…..2648
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY…..2650
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY…..2652
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…..2657
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…..2658
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…..2659
REMOVAL AND INSTALLATION OF SPROCKET…..2666
REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…..2667
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY…..2668
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…..2675
DISASSEMBLY AND ASSEMBLY OF TRAVEL ROLLER ASSEMBLY…..2677
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…..2678
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY…..2681
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY…..2683
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY…..2685
REMOVAL AND INSTALLATION OF OPERATOR'S CAB…..2687
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY…..2690
REMOVAL AND INSTALLATION OF PUMP CONTROLLER…..2691
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER…..2692
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…..2693
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY…..2696
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY…..2697
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY…..2699
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT…..2702
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY…..2703
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…..2706
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…..2710
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…..2712
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY…..2713
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY…..2714
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…..2715
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…..2720
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)…..2723
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY…..2733
90 OTHERS…..2739
HYDRAULIC CIRCUIT DIAGRAM (1/2)…..2740
HYDRAULIC CIRCUIT DIAGRAM (2/2)…..2741
ELECTRICAL CIRCUIT DIAGRAM(1/5)…..2742
ELECTRICAL CIRCUIT DIAGRAM(2/5)…..2743
ELECTRICAL CIRCUIT DIAGRAM(3/5)…..2744
ELECTRICAL CIRCUIT DIAGRAM(4/5)…..2745
ELECTRICAL CIRCUIT DIAGRAM(5/5)…..2746
AIR CONDITIONER ELECTRICAL CIRCUIT…..2747
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)…..2748
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)…..2749
SEBM033012 – Hydraulic Excavator PC400-7, PC400LC-7, PC450-7, PC450LC-7 Shop Manual…..2750
COVER…..2750
CONTENTS…..2751
01 GENERAL…..2785
SPECIFICATION DRAWINGS…..2786
SPECIFICATIONS…..2790
WEIGHT TABLE…..2796
FUEL, COOLANT AND LUBRICANTS…..2800
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…..2803
ENGINE RELATED PARTS…..2804
RADIATOR・OIL COOLER・AFTERCOOLER…..2806
POWER TRAIN…..2807
FINAL DRIVE…..2808
SPROCKET…..2810
SWING MACHINERY…..2812
SWING CIRCLE…..2814
TRACK FRAME AND RECOIL SPRING…..2815
IDLER…..2817
CARRIER ROLLER…..2819
TRACK ROLLER…..2820
TRACK SHOE…..2821
HYDRAULIC PIPING DRAWING…..2825
HYDRAULIC TANK…..2827
HYDRAULIC PUMP…..2828
LS(PC)-EPC VALVE…..2847
VARIABLE VOLUME VALVE…..2850
CONTROL VALVE…..2852
CLSS…..2876
FUNCTIONS AND OPERATION BY VALVE…..2880
ATTACHMENT CIRCUIT SELECTOR VALVE…..2922
HOLDING VALVE…..2924
SWING MOTOR…..2930
REVERSAL PREVENTION VALVE…..2935
CENTER SWIVEL JOINT…..2937
TRAVEL MOTOR…..2938
VALVE CONTROL…..2949
TRAVEL PPC SHUTTLE VALVE…..2950
WORK EQUIPMENT・SWING PPC VALVE…..2954
TRAVEL PPC VALVE…..2958
SERVICE PPC VALVE…..2965
SOLENOID VALVE…..2966
PPC ACCUMULATOR…..2968
RETURN OIL FILTER…..2969
HYDRAULIC CYLINDER…..2970
WORK EQUIPMENT…..2974
AIR CONDITIONER…..2982
ENGINE CONTROL…..2983
ELECTRONIC CONTROL SYSTEM…..2988
MONITOR SYSTEM…..3015
7-SEGMENT MONITOR SYSTEM…..3036
SENSOR…..3043
20 TESTING AND ADJUSTING…..3046
STANDARD VALUE TABLE FOR ENGINE…..3047
STANDARD VALUE TABLE FOR CHASSIS (BACKHOE SPECIFICATION)…..3048
STANDARD VALUE TABLE FOR CHASSIS (LOADING SHOVEL SPECIFICATION)…..3057
TESTING AND ADJUSTING…..3066
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE…..3067
MEASURING ENGINE SPEED…..3069
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…..3070
MEASURING EXHAUST TEMPERATURE…..3071
MEASURING EXHAUST GAS COLOR…..3072
ADJUSTING VALVE CLEARANCE…..3073
MEASURING COMPRESSION PRESSURE…..3075
MEASURING BLOW-BY PRESSURE…..3077
MEASURING ENGINE OIL PRESSURE…..3078
HANDLING OF FUEL SYSTEM DEVICES…..3079
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…..3079
MEASURING FUEL PRESSURE…..3080
BLEEDING AIR FROM FUEL CIRCUIT…..3081
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE…..3083
ADJUSTING ENGINE SPEED SENSOR…..3084
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION…..3085
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…..3086
MEASURING CLEARANCE OF SWING CIRCLE BEARING…..3087
TESTING AND ADJUSTING TRACK SHOE TENSION…..3088
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…..3089
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT…..3093
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…..3094
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT…..3097
MEASURING SOLENOID VALVE OUTPUT PRESSURE…..3102
MEASURING PPC VALVE OUTPUT PRESSURE…..3105
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…..3107
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT…..3108
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT…..3110
MEASURING OIL LEAKAGE…..3111
BLEEDING AIR FROM EACH PART…..3114
TESTING PROCEDURE OF DIODE…..3117
SPECIAL FUNCTIONS OF MONITOR PANEL…..3118
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL…..3145
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER…..3164
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM…..3165
PM-CLINIC SERVICE…..3167
TROUBLESHOOTING…..3174
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..3175
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..3176
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..3177
CHECKS BEFORE TROUBLESHOOTING…..3185
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING…..3186
CONNECTOR ARRANGEMENT DIAGRAM AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM…..3190
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..3207
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE…..3243
CONNECTION TABLE OF FUSE BOX…..3246
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED…..3247
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..3249
ERROR CODE IN ELECTRICAL SYSTEM [E112](SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)…..3251
ERROR CODE IN ELECTRICAL SYSTEM [E113](SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)…..3253
ERROR CODE IN ELECTRICAL SYSTEM [E114](SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM)…..3255
ERROR CODE IN ELECTRICAL SYSTEM [E115](ABNORMAL WINDSHIELD WIPER MOTION)…..3257
ERROR CODE IN ELECTRICAL SYSTEM [E116](ABNORMALITY IN RETRACTING WINDSHIELD WIPER) …..3259
ERROR CODE IN ELECTRICAL SYSTEM (E117](ENG. CONTROLLER S-NET COMM. ERR.)…..3261
ERROR CODE IN ELECTRICAL SYSTEM (E118](PUMP CONTROLLER S-NET COMM. ERR.)…..3263
ERROR CODE IN ELECTRICAL SYSTEM (E128](MONITOR COMM. ABNORMALITY)…..3265
ERROR CODE IN ELECTRICAL SYSTEM (E201](SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)…..3267
ERROR CODE IN ELECTRICAL SYSTEM [E203](SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)…..3268
ERROR CODE IN ELECTRICAL SYSTEM [E204](SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)…..3270
ERROR CODE IN ELECTRICAL SYSTEM [E205](SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)…..3271
ERROR CODE IN ELECTRICAL SYSTEM [E206](SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID)…..3272
ERROR CODE IN ELECTRICAL SYSTEM [E211](DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)…..3273
ERROR CODE IN ELECTRICAL SYSTEM [E213](DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)…..3274
ERROR CODE IN ELECTRICAL SYSTEM [E214](DISCONNECTION OF MERGE/DIVIDE SOLENOID)…..3276
ERROR CODE IN ELECTRICAL SYSTEM [E215](DISCONNECTION IN 2-STAGE RELIEF SOLENOID)…..3277
ERROR CODE IN ELECTRICAL SYSTEM [E216](DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)…..3278
ERROR CODE IN ELECTRICAL SYSTEM [E217](ABNORMAL INPUT MODEL CODE)…..3279
ERROR CODE IN ELECTRICAL SYSTEM [E218](S-NET COMM. DISC.)…..3281
ERROR CODE IN ELECTRICAL SYSTEM [E222](SHORT-CIRCUITING IN LS-EPC SOLENOID)…..3283
ERROR CODE IN ELECTRICAL SYSTEM [E223](DISCONNECTION IN LS-EPC SOLENOID SYSTEM)…..3284
ERROR CODE IN ELECTRICAL SYSTEM [E224](F PUMP P. SENSOR ABNORMALITY)…..3285
ERROR CODE IN ELECTRICAL SYSTEM [E225](R PUMP P. SENSOR ABNORMALITY)…..3287
ERROR CODE IN ELECTRICAL SYSTEM [E226](P. SENSOR POWER ABNORMALITY)…..3289
ERROR CODE IN ELECTRICAL SYSTEM [E227](ABNORMALITY IN ENGINE ROTATION SENSOR) …..3291
ERROR CODE IN ELECTRICAL SYSTEM [E228](SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)…..3292
ERROR CODE IN ELECTRICAL SYSTEM [E232](SHORT-CIRCUITING IN PC-EPC SOLENOID)…..3293
ERROR CODE IN ELECTRICAL SYSTEM [E233](DISCONNECTION IN PC-EPC SOLENOID SYSTEM)…..3295
ERROR CODE IN ELECTRICAL SYSTEM [E238](DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY)…..3297
ERROR CODE IN ELECTRICAL SYSTEM [E245](SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)…..3299
ERROR CODE IN ELECTRICAL SYSTEM [E246](DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)…..3300
ERROR CODE IN ELECTRICAL SYSTEM [E247](ARM IN PPC PRESSURE SENSOR ABNORMALITY)…..3301
ERROR CODE IN ELECTRICAL SYSTEM [E248](BUCKET CURL PPC PRESSURE SENSOR ABNORMALITY)…..3303
ERROR CODE IN ELECTRICAL SYSTEM [E257](PUMP ABNORMALITY)…..3305
ERROR CODE IN ELECTRICAL SYSTEM [E315](BATTERY RELAY DRIVE S/C)…..3307
ERROR CODE IN ELECTRICAL SYSTEM [E91B](ENGINE NE SENSOR PROBLEM)…..3309
ERROR CODE IN ELECTRICAL SYSTEM [E91C](ENGINE G SENSOR PROBLEM)…..3310
ERROR CODE IN ELECTRICAL SYSTEM [E920](ENGINE TYPE SELECTION ERROR)…..3311
ERROR CODE IN ELECTRICAL SYSTEM [E921](ENGINE TYPE MISMATCH)…..3313
ERROR CODE IN ELECTRICAL SYSTEM [E931](FUEL DIAL SYS. ERROR)…..3314
ERROR CODE IN ELECTRICAL SYSTEM [E934](ENGINE COOLANT SENSOR HI ERROR)…..3316
ERROR CODE IN ELECTRICAL SYSTEM [E936](ENGINE OIL PRESS. SW. ERROR)…..3318
ERROR CODE IN ELECTRICAL SYSTEM [E93C](ENGINE BOOST SENSOR ERROR)…..3320
ERROR CODE IN ELECTRICAL SYSTEM [E93D](ENGINE FUEL TEMP. SENSOR ERROR)…..3322
ERROR CODE IN ELECTRICAL SYSTEM [E953](ENGINE COMM. ABNORMALITY)…..3324
ERROR CODE IN ELECTRICAL SYSTEM [E954](SHORT ENGINE STARTER SW.)…..3326
ERROR CODE IN ELECTRICAL SYSTEM [E955](ENGINE S-NET ERROR)…..3328
ERROR CODE IN ELECTRICAL SYSTEM [E956](ENGINE POWER FAILURE (1))…..3330
ERROR CODE IN ELECTRICAL SYSTEM [E957](ENGINE POWER FAILURE (2))…..3332
ERROR CODE IN ELECTRICAL SYSTEM [E95A](ENGINE Q-ADJ. SW. SIGNAL ERROR)…..3334
ERROR CODE IN ELECTRICAL SYSTEM [E96A](ENGINE COOLANT SENSOR LO ERROR)…..3335
ERROR CODE IN ELECTRICAL SYSTEM [E970](PCV1 OVER CURRENT)…..3337
ERROR CODE IN ELECTRICAL SYSTEM [E971](PCV2 OVER CURRENT)…..3338
ERROR CODE IN ELECTRICAL SYSTEM [E974](PCV1 LINE CUT)…..3339
ERROR CODE IN ELECTRICAL SYSTEM [E975](PCV2 LINE CUT)…..3340
ERROR CODE IN ELECTRICAL SYSTEM [E977](RAIL PRESS. SENSOR ERROR)…..3341
ERROR CODE IN ELECTRICAL SYSTEM [E979](RAIL PRESS. HIGH)…..3343
ERROR CODE IN ELECTRICAL SYSTEM [E97A](RAIL PRESS. ABNORMAL)…..3343
ERROR CODE IN ELECTRICAL SYSTEM [E97B](RAIL PRESS. LOW)…..3344
ERROR CODE IN ELECTRICAL SYSTEM [E97C](RAIL PRESS. TOO LOW)…..3346
ERROR CODE IN ELECTRICAL SYSTEM [E97D](RAIL PRESS. CUT OF CONTROL)…..3346
ERROR CODE IN ELECTRICAL SYSTEM [E980](ENG. CONTROLLER ABNORMALITY)…..3347
ERROR CODE IN ELECTRICAL SYSTEM [E981](FUEL INJECTOR 1 DISC.)…..3349
ERROR CODE IN ELECTRICAL SYSTEM [E982](FUEL INJECTOR 2 DISC.)…..3350
ERROR CODE IN ELECTRICAL SYSTEM [E983](FUEL INJECTOR 3 DISC.)…..3351
ERROR CODE IN ELECTRICAL SYSTEM [E984](FUEL INJECTOR 4 DISC.)…..3352
ERROR CODE IN ELECTRICAL SYSTEM [E985](FUEL INJECTOR 5 DISC.)…..3353
ERROR CODE IN ELECTRICAL SYSTEM [E986](FUEL INJECTOR 6 DISC.)…..3354
ERROR CODE IN ELECTRICAL SYSTEM [E98A](FUEL INJECTOR 1-3 S/C)…..3355
ERROR CODE IN ELECTRICAL SYSTEM [E98B](FUEL INJECTOR 4-6 S/C)…..3357
ERROR CODE IN MECHANICAL SYSTEM [A000N1](ENGINE HIGH-IDLING SPEED OUT OF STANDARD)…..3359
ERROR CODE IN MECHANICAL SYSTEM [A000N2](ENGINE LOW-IDLING SPEED OUT OF STANDARD)…..3359
FAILURE CODE IN MECHANICAL SYSTEM [AA10NX](AIRCLEANER CLOGGING…..3360
FAILURE CODE IN MECHANICAL SYSTEM [AB00KE](CHARGE VOLTAGE LOW)…..3362
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG](ENG. OIL PRESS. LOW)…..3364
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK](ENG. OIL LEVEL LOW)…..3366
FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS](ENG. WATER OVERHEAT)…..3367
FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK](ENG. WATER LVL LOW)…..3368
FAILURE CODE IN MECHANICAL SYSTEM [B@HANS](HYDR. OIL OVERHEAT)…..3369
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…..3370
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..3372
E-1 ENGINE DOES NOT START(THE ENGINE DOES NOT ROTATE)…..3373
E-2 PREHEATER DOES NOT OPERATE…..3376
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK…..3378
E-4 AUTO-DECELERATOR DOES NOT OPERATE…..3379
E-5 ALL WORK EQUIPMENT,SWING AND TRAVEL DO NOT MOVE…..3380
E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE…..3382
E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY…..3383
E-8 ATTACHMENT CIRCUIT DOES NOT CHANGE…..3385
E-9 NO DISPLAY IN MONITOR PANEL AT ALL…..3387
E-10 PART OF DISPLAY ON MONITOR PANEL IS MISSING…..3388
E-11 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL…..3388
E-12 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING…..3389
E-13 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY…..3390
E-14 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY…..3392
E-15 FUEL GAUGE DOES NOT DISPLAY CORRECTLY…..3393
E-16 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY…..3394
E-17 WHEN MONITOR SWITCH IS OPERATED,NOTHING IS DISPLAYED…..3396
E-18 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK…..3398
E-19 ALARM BUZZER CANNOT BE CANCELLED…..3402
E-20 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..3403
E-21 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..3404
E-22 "ARM IN" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION…..3405
E-23 "ARM DUMPING " IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..3406
E-24 "BUCKET CURL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION…..3407
E-25 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..3408
E-26 "SWING" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION…..3409
E-27 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..3411
E-28 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..3413
E-29 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…..3415
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING…..3417
E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM…..3419
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H MODE)…..3430
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM…..3431
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..3433
H-1 ALL WORK EQUIPMENT LACK POWER,OR TRAVEL AND SWING SPEEDS ARE SLOW…..3434
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS…..3435
H-3 NO WORK EQUIPMENT,TRAVEL OR SWING MOVE…..3436
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP…..3436
H-5 AUTO-DECELERATOR DOES NOT WORK…..3437
H-6 FINE CONTROL MODE DOES NOT FUNCTION…..3437
H-7 BOOM MOVES SLOWLY OR LACKS POWER…..3438
H-8 ARM MOVES SLOWLY OR LACKS POWER…..3439
H-9 BUCKET MOVES SLOWLY OR LACKS POWER…..3440
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION…..3440
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT…..3441
H-12 WORK EQUIPMENT HAS BIG TIME LAG…..3442
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT…..3442
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK…..3442
H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK…..3443
H-16 IN COMPOUND OPERATION,WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY…..3444
H-17 IN SWING + BOOM RAISE OPERATION,BOOM MOVES SLOWLY…..3444
H-18 IN SWING + TRAVEL,TRAVEL SPEED DROPS SHARPLY…..3444
H-19 MACHINE SWERVES IN TRAVEL…..3445
H-20 MACHINE TRAVELS SLOWLY…..3446
H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER…..3447
H-22 TRAVEL SPEED DOES NOT SHIFT,OR IT IS SLOWER OR FASTER THAN PRESET SPEED…..3448
H-23 TRACK SHOE DOES NOT TURN(ON ONE SIDE ONLY)…..3449
H-24 MACHINE DOES NOT SWING…..3450
H-25 SWING ACCELERATION IS POOR,OR SWING SPEED IS SLOW…..3451
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING…..3452
H-27 THERE IS BIG SHOCK WHEN STOPPING SWING…..3453
H-28 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING…..3453
H-29 SWING NATURAL DRIFT IS TOO BIG…..3454
H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE…..3455
H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED…..3455
TROUBLESHOOTING OF ENGINE (S MODE)…..3456
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..3457
METHOD OF USING TROUBLESHOOTING CHARTS…..3458
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..3461
S-2 ENGINE DOES NOT START…..3462
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)…..3465
S-4 ENGINE STOPS DURING OPERATIONS…..3466
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)…..3467
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…..3468
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)…..3469
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..3470
S-9 OIL BECOMES CONTAMINATED QUICKLY…..3471
S-10 FUEL CONSUMPTION IS EXCESSIVE…..3472
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)…..3473
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..3474
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)…..3475
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)…..3476
S-15 ABNORMAL NOISE IS MADE…..3477
S-16 VIBRATION IS EXCESSIVE…..3478
30 DISASSEMBLY AND ASSEMBLY…..3479
HOW TO READ THIS MANUAL…..3480
COATING MATERIALS LIST…..3482
SPECIAL TOOL LIST…..3485
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…..3495
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…..3502
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…..3506
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…..3509
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY…..3512
REMOVAL AND INSTALLATION OF NOZZLE TIP…..3515
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY…..3517
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…..3518
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY…..3520
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY…..3522
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…..3527
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…..3528
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…..3529
REMOVAL AND INSTALLATION OF SPROCKET…..3536
REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…..3537
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY…..3538
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…..3545
DISASSEMBLY AND ASSEMBLY OF TRAVEL ROLLER ASSEMBLY…..3547
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…..3548
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY…..3551
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY…..3553
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY…..3555
REMOVAL AND INSTALLATION OF OPERATOR'S CAB…..3557
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY…..3560
REMOVAL AND INSTALLATION OF PUMP CONTROLLER…..3561
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER…..3562
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…..3563
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY…..3566
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY…..3567
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY…..3569
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT…..3572
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY…..3573
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…..3576
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…..3580
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…..3582
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY…..3583
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY…..3585
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…..3587
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…..3592
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)…..3595
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY…..3605
90 OTHERS…..3611
HYDRAULIC CIRCUIT DIAGRAM (1/2)…..3613
HYDRAULIC CIRCUIT DIAGRAM (2/2)…..3614
ELECTRICAL CIRCUIT DIAGRAM (1/6)…..3615
ELECTRICAL CIRCUIT DIAGRAM (2/6)…..3616
ELECTRICAL CIRCUIT DIAGRAM (3/6)…..3617
ELECTRICAL CIRCUIT DIAGRAM (4/6)…..3618
ELECTRICAL CIRCUIT DIAGRAM (5/6)…..3619
ELECTRICAL CIRCUIT DIAGRAM (6/6)…..3620
AIR CONDITIONER ELECTRICAL CIRCUIT…..3621
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)…..3622
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)…..3623
SEN02223-05 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Shop Manual…..3624
COVER…..3624
00 Index and foreword…..0
Index…..3626
Composition of shop manual…..3627
Table of contents…..3629
Foreword and general information…..3638
Safety notice…..3639
How to read the shop manual…..3644
Explanation of terms for maintenance standard…..3646
Handling of electric equipment and hydraulic component…..3648
Handling of connectors newly used for engines…..3657
How to read electric wire code…..3660
Precautions when carrying out operation…..3663
Method of disassembling and connecting push-pull type coupler…..3666
Standard tightening torque table…..3669
Conversion table…..3673
01 Specification…..0
Specification and technical data…..3680
Specification dimension drawings…..3681
Specifications…..3683
Weight table…..3687
Table of fuel, coolant and lubricants…..3691
10 Structure, function and maintenance standard…..0
Engine and cooling system…..3694
Engine related parts…..3695
Radiator, oil cooler and aftercooler…..3696
Power train…..3698
Power train…..3699
Swing circle…..3700
Swing machinery…..3701
Final drive…..3703
Sprocket…..3705
Undercarriage and frame…..3708
Track frame and recoil spring…..3709
Idler…..3711
Carrier roller…..3713
Track roller…..3714
Track shoe…..3715
Hydraulic system, Part 1…..3720
Hydraulic equipment layout drawing…..3721
Hydraulic tank and filter…..3723
Hydraulic pump…..3725
Hydraulic system, Part 2…..3750
Control valve…..3751
CLSS…..3763
Functions and operation by valve…..3767
Merge-divider valve…..3782
Attachment circuit selector valve…..3807
Holding valve…..3809
Hydraulic system, Part 3…..3816
Valve control…..3817
PPC valve…..3819
Solenoid valve…..3835
PPC accumulator…..3837
Return oil filter…..3838
Center swivel joint…..3839
Travel motor…..3840
Swing motor…..3852
Hydraulic cylinder…..3861
Work equipment…..3864
Work equipment…..3865
Dimensions of components…..3867
Cab and its attachments…..3872
Air conditioner piping…..3873
Electrical system…..3876
Engine control…..3877
Electrical control system…..3888
Monitor system…..3913
Sensors…..3940
KOMTRAX terminal system…..3943
20 Standard value table…..0
Standard service value table…..3946
Standard value table for engine…..3947
Standard value table for chassis related parts…..3948
Standard value table for chassis related parts (Loading shovel specification)…..3957
30 Testing and adjusting…..0
Testing and adjusting, Part 1…..3968
Tools for testing, adjusting and troubleshooting…..3970
Sketches of special tools…..3974
Testing engine speed…..3975
Testing air boost pressure…..3976
Testing exhaust temperature…..3977
Testing exhaust gas color…..3978
Adjusting valve clearance…..3979
Testing compression pressure…..3981
Testing blow-by pressure…..3983
Testing engine oil pressure…..3984
Testing EGR valve drive pressure…..3985
Handling fuel system parts…..3986
Releasing residual pressure from fuel system…..3986
Testing fuel pressure…..3987
Handling during cylinder cut-out operation…..3988
Handling during no injection cranking operation…..3988
Testing fuel return and leakage…..3989
Bleeding air from fuel circuit…..3992
Checking fuel circuit for leakage…..3994
Checking and adjusting fan belt and alternator belt…..3995
Checking and adjusting air conditioner compressor belt tension…..3996
Testing swing circle bearing clearance…..3997
Checking and adjusting track shoe tension…..3998
Testing and adjustment oil pressure in work equipment, swing, and travel circuits…..3999
Testing control circuit basic pressure…..4003
Checking and adjusting pump PC control circuit oil pressure…..4004
Checking and adjusting pump LS control circuit oil pressure…..4007
Testing solenoid valve output pressure…..4012
Testing PPC valve output pressure…..4015
Adjusting play of work equipment and swing PPC valves…..4017
Inspecting locations of hydraulic drift of work equipment…..4018
Releasing residual pressure from hydraulic circuit…..4020
Testing oil leakage amount…..4021
Bleeding air from various parts…..4024
Testing and adjusting, Part 2…..4028
Special functions of machine monitor…..4029
Testing and adjusting, Part 3…..4084
Handling voltage circuit of engine controller…..4085
Preparation work for troubleshooting of electrical system…..4086
Procedure for testing diodes…..4091
Pm Clinic service…..4092
Undercarriage troubleshooting report…..4099
40 Troubleshooting…..0
Failure code table and fuse locations…..4102
Failure code table…..4103
Fuse locations…..4106
General Information on troubleshooting…..4112
Points to remember when troubleshooting…..4113
Sequence of events in troubleshooting…..4114
Check before troubleshooting…..4115
Classification and troubleshooting steps…..4116
Information in troubleshooting table…..4117
Possible problems and troubleshooting No…..4119
Connection table for connector pin numbers…..4121
T- branch box and T- branch adapter table…..4157
Troubleshooting by failure code, Part 1…..4162
Failure code [989L00] Engine Controller Lock Caution 1…..4164
Failure code [989M00] Engine Controller Lock Caution 2…..4165
Failure code [989N00] Engine Controller Lock Caution 3…..4166
Failure code [AA10NX] Air cleaner Clogging…..4167
Failure code [AB00KE] Charge Voltage Low…..4169
Failure code [B@BAZG] Eng Oil Press Low…..4171
Failure code [B@BAZK] Eng Oil Level Low…..4173
Failure code [B@BCNS] Eng Water Overheat…..4175
Failure code [B@BCZK] Eng Water Level Low…..4177
Failure code [B@HANS] Hydr Oil Overheat…..4179
Failure code [CA111] EMC Critical Internal Failure…..4180
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…..4182
Failure code [CA122] Chg Air Press Sensor High Error…..4183
Failure code [CA123] Chg Air Press Sensor Low Error…..4185
Failure code [CA131] Throttle Sensor High Error…..4187
Failure code [CA132] Throttle Sensor Low Error…..4189
Failure code [CA135] Eng Oil Press Sensor High Error…..4191
Failure code [CA141] Eng Oil Press Sensor Low Error…..4193
Failure code [CA144] Coolant Temp Sensor High Error…..4194
Failure code [CA145] Coolant Temp Sensor Low Error…..4196
Failure code [CA153] Chg Air Temp Sensor High Error…..4198
Failure code [CA154] Chg Air Temp Sensor Low Error…..4200
Failure code [CA187] Sens Supply 2 Volt Low Error…..4202
Failure code [CA221] Ambient Press Sens High Error…..4204
Failure code [CA222] Ambient Press Sens Low Error…..4206
Failure code [CA227] Sens Supply 2 Volt High Error…..4208
Failure code [CA234] Eng Overspeed…..4209
Failure code [CA238] Ne Speed Sens Supply Volt Error…..4210
Failure code [CA263] Fuel Temp Sensor High Error…..4211
Failure code [CA265] Fuel Temp Sensor Low Error…..4213
Failure code [CA271] IMV/PCV1 Short Error…..4214
Failure code [CA272] IMV/PCV1 Open Error…..4216
Failure code [CA273] PCV2 Short Error…..4218
Failure code [CA274] PCV2 Open Error…..4220
Failure code [CA322] Inj #1 Open/Short Error…..4222
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error…..4224
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error…..4226
Failure code [CA325] Inj #6 Open/Short Error…..4228
Failure code [CA331] Inj #2 Open/Short Error…..4230
Failure code [CA332] Inj #4 Open/Short Error…..4232
Troubleshooting by failure code, Part 2…..4236
Failure code [CA342] Calibration Code Incompatibility…..4238
Failure code [CA351] Injectors Drive Circuit Error…..4239
Failure code [CA352] Sens Supply 1 Volt Low Error…..4241
Failure code [CA386] Sens Supply 1 Volt High Error…..4243
Failure code [CA441] Battery Voltage Low Error…..4245
Failure code [CA442] Battery Voltage High Error…..4247
Failure code [CA449] Rail Press Very High Error…..4249
Failure code [CA451] Rail Press Sensor High Error…..4252
Failure code [CA452] Rail Press Sensor Low Error…..4254
Failure code [CA553] Rail Press High Error…..4256
Failure code [CA554] Rail Press Sensor In Range Error…..4257
Failure code [CA559] Rail Press Low Error…..4258
Failure code [CA689] Eng Ne Speed Sensor Error…..4262
Failure code [CA731] Eng Bkup Speed Sens Phase Error…..4264
Failure code [CA757] All Continuous Data Lost Error…..4265
Failure code [CA778] Eng Bkup Speed Sensor Error…..4267
Failure code [CA1228] EGR valve servo error 1…..4269
Failure code [CA1625] EGR valve servo error 2…..4270
Failure code [CA1633] KOMNET Datalink Timeout Error…..4271
Failure code [CA2185] Throt Sens Sup Volt High Error…..4273
Failure code [CA2186] Throt Sens Sup Volt Low Error…..4275
Failure code [CA2249] Rail Press Very Low Error…..4276
Failure code [CA2271] EGR valve lift sensor high error…..4277
Failure code [CA2272] EGR valve lift sensor low error…..4279
Failure code [CA2351] EGR valve solenoid operation short circuit…..4280
Failure code [CA2352] EGR valve solenoid operation disconnect…..4282
Failure code [CA2555] Grid Htr Relay Volt Low Error…..4283
Failure code [CA2556] Grid Htr Relay Volt High Error…..4285
Failure code [D110KB] Battery Relay Drive S/C…..4287
Failure code [D19JKZ] Personal Code Relay Abnormality…..4289
Failure code [D862KA] GPS Antenna Discon…..4291
Failure code [DA22KK] Pump Solenoid Power Low Error…..4292
Failure code [DA25KP] 5V sensor power supply output 1 abnormality…..4294
Failure code [DA29KQ] Model Selection Abnormality…..4297
Troubleshooting by failure code, Part 3…..4300
Failure code [DA2RMC] CAN Discon (Pump con detected)…..4302
Failure code [DAF8KB] Short circuit in camera power supply…..4304
Failure code [DAFGMC] GPS Module Error…..4306
Failure code [DAFRMC] CAN discon (Monitor detected)…..4307
Failure code [DGH2KB] Hyd Oil Sensor Short…..4309
Failure code [DHPAMA] F Pump Press Sensor Abnormality…..4310
Failure code [DHPBMA] R Pump Press Sensor Abnormality…..4312
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality…..4314
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality…..4316
Failure code [DHX1MA] Overload Sensor Abnormality (Analog)…..4318
Failure code [DW43KA] Travel Speed Sol. Open Circuit…..4319
Failure code [DW43KB] Travel Speed Sol. Short Circuit…..4321
Failure code [DW45KA] Swing Brake Sol. Open Circuit…..4323
Failure code [DW45KB] Swing Brake Sol. Short Circuit…..4325
Failure code [DW91KA] Travel Junction Sol.Open Circuit…..4327
Failure code [DW91KB] Travel Junction Sol. Short Circuit…..4329
Failure code [DWA2KA] Attachment Sol Open Circuit…..4331
Failure code [DWA2KB] Attachment Sol Short Circuit…..4332
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit…..4333
Failure code [DWJ0KB] Merge-divider Sol. Short Circuit…..4335
Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit…..4337
Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit…..4339
Failure code [DXA0KA] PC-EPC Sol. Open Circuit…..4341
Failure code [DXA0KB] PC-EPC Sol. Short Circuit…..4343
Failure code [DXE0KA] LS-EPC Sol. Open Circuit…..4345
Failure code [DXE0KB] LS-EPC Sol. Short Circuit…..4347
Failure code [DXE4KA] Service Current EPC Open Circuit…..4349
Failure code [DXE4KB] Service Current EPC Short Circuit…..4350
Failure code [DY20KA] Wiper Working Abnormality…..4351
Failure code [DY20MA] Wiper Parking Abnormality…..4353
Failure code [DY2CKA] Washer Drive Open Discon…..4355
Failure code [DY2CKB] Washer Drive Short Circuit…..4357
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit…..4359
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit…..4361
Troubleshooting of electrical system (E-mode)…..4364
Before carrying out troubleshooting of electrical system…..4367
Information contained in troubleshooting table…..4369
E-1 Engine does not start…..4370
E-2 Auto-decelerator does not operate…..4373
E-3 Automatic warming-up system does not operate…..4375
E-4 Preheater does not operate…..4377
E-5 All work equipment, swing, and travel mechanism do not move…..4379
E-6 Power maximizing function does not operate…..4381
E-7 Machine monitor does not display at all…..4383
E-8 Machine monitor does not display some items…..4385
E-9 Contents of display by machine monitor are different from applicable machine…..4385
E-10 Fuel level monitor was lighted in red while engine running…..4386
E-11 Engine coolant temperature gauge does not indicate normally…..4387
E-12 Hydraulic oil temperature gauge does not indicate normally…..4389
E-13 Fuel level gauge does not indicate normally…..4390
E-14 Swing lock monitor does not indicate normally…..4391
E-15 When monitor switch is operated, monitor displays nothing…..4393
E-16 Windshield wiper and window washer do not operate…..4395
E-17 Machine push-up function does not operate normally…..4399
E-18 Monitoring function fails to display “boom raise” normally…..4401
E-19 Monitoring function fails to display “boom lower” normally…..4403
E-20 Monitoring function fails to display “arm IN” normally…..4405
E-21 Monitoring function fails to display “arm OUT” normally…..4407
E-22 Monitoring function fails to display “bucket CURL” normally…..4409
E-23 Monitoring function fails to display “bucket DUMP” normally…..4411
E-24 Monitoring function fails to display “swing” normally…..4413
E-25 Monitoring function fails to display “travel” normally…..4415
E-26 Monitoring function fails to display “travel differential pressure” normally…..4417
E-27 Monitoring function fails to display “service” normally…..4419
E-28 KOMTRAX system does not operate normally…..4421
E-29 Air conditioner does not operate…..4423
E-30 Travel alarm does not sound or does not stop sounding…..4425
E-31 Horn does not sound…..4427
Troubleshooting of hydraulic and mechanical system (H-mode)…..4430
System chart for hydraulic and mechanical system…..4433
Information contained in troubleshooting table…..4435
H-1 All work equipment lack power, or travel and swing speeds are slow…..4437
H-2 Engine speed sharply drops or engine stalls…..4439
H-3 No work equipment, swing or travel move…..4440
H-4 Abnormal noise is heard from around hydraulic pump…..4440
H-5 Auto-decelerator does not work…..4441
H-6 Fine control mode does not function or responds slow…..4441
H-7 Boom moves slowly or lacks power…..4442
H-8 Arm moves slowly or lacks power…..4443
H-9 Bucket moves slowly or lacks power…..4444
H-10 Work equipment does not move in its single operation…..4444
H-11 Work equipment has a bit too fast hydraulic drift…..4445
H-12 Work equipment has big time lag…..4447
H-13 Other work equipment moves when relieving single circuit…..4447
H-14 Power max. switch does not operate…..4447
H-15 Machine push-up function does not operate…..4448
H-16 In compound operation of work equipment, speed of part loaded more is low…..4449
H-17 When machine swings and raises boom simultaneously, boom rising speed is low…..4449
H-18 When machine swings and travels simultaneously, travel speed lowers largely…..4449
H-19 Machine deviates during travel…..4450
H-20 Travel speed is low…..4451
H-21 Machine is not steered well or steering power is low…..4452
H-22 Travel speed does not change or travel speed is low or high…..4453
H-23 Travel system does not move (only one side)…..4454
H-24 Upper structure does not swing…..4455
H-25 Swing acceleration or swing speed is low…..4457
H-26 Upper structure overruns remarkably when it stops swinging…..4459
H-27 Large shock is made when upper structure stops swinging…..4460
H-28 Large sound is made when upper structure stops swinging…..4460
H-29 Hydraulic drift of swing is large…..4461
H-30 Attachment circuit is not changed…..4462
H-31 Oil flow in attachment circuit cannot be controlled…..4462
Troubleshooting of engine (S-mode)…..4464
Method of using troubleshooting chart…..4466
S-1 Starting performance is poor…..4469
S-2 Engine does not start…..4471
S-3 Engine does not pick up smoothly…..4475
S-4 Engine stops during operations…..4476
S-5 Engine does not rotate smoothly…..4477
S-6 Engine lacks output (or lacks power)…..4478
S-7 Exhaust smoke is black (incomplete combustion)…..4479
S-8 Oil consumption is excessive (or exhaust smoke is blue)…..4480
S-9 Oil becomes contaminated quickly…..4481
S-10 Fuel consumption is excessive…..4482
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…..4483
S-12 Oil pressure drops…..4484
S-13 Oil level rises (Entry of coolant or fuel)…..4485
S-14 Coolant temperature becomes too high (overheating)…..4487
S-15 Abnormal noise is made…..4488
S-16 Vibration is excessive…..4489
50 Disassembly and assembly…..0
General information on disassembly and assembly…..4492
How to read this manual…..4493
Coating materials list…..4495
Special tool list…..4498
Sketches of special tools…..4501
Engine and cooling system…..4508
Removal and installation of fuel supply pump assembly…..4509
Removal and installation of fuel injector assembly…..4513
Removal and installation of engine front seal…..4519
Removal and installation of engine rear seal…..4522
Removal and installation of cylinder head assembly…..4527
Removal and installation of radiator assembly…..4536
Removal and installation of hydraulic oil cooler assembly…..4538
Removal and installation of aftercooler assembly…..4540
Removal and installation of engine and hydraulic oil pump assembly…..4541
Power train…..4550
Removal and installation of travel motor and final drive assembly…..4551
Disassembly and assembly of final drive assembly…..4552
Removal and installation of swing motor and swing machinery assembly…..4560
Disassembly and assembly of swing motor and swing machinery assembly…..4561
Removal and installation of swing circle assembly…..4568
Undercarriage and frame…..4570
Disassembly and assembly of carrier roller assembly…..4571
Disassembly and assembly of track roller assembly…..4573
Disassembly and assembly of idler assembly…..4574
Disassembly and assembly of recoil spring assembly…..4577
Removal and installation of sprocket…..4579
Expansion and installation of track shoe assembly…..4580
Removal and installation of revolving frame assembly…..4582
Removal and installation of counterweight assembly…..4585
Hydraulic system…..4590
Removal and installation of center swivel joint assembly…..4591
Disassembly and assembly of center swivel joint assembly…..4593
Removal and installation of hydraulic tank assembly…..4594
Removal and installation of control valve assembly…..4596
Disassembly and assembly of control valve assembly…..4599
Removal and installation of hydraulic pump assembly…..4603
Removal and installation of oil seal in hydraulic pump input shaft…..4606
Disassembly and assembly of work equipment PPC valve assembly…..4607
Disassembly and assembly of travel PPC valve assembly…..4609
Disassembly and assembly of hydraulic cylinder assembly…..4612
Work equipment…..4620
Removal and installation of work equipment assembly…..4621
Cab and its attachments…..4626
Removal and installation of operator cab assembly…..4627
Removal and installation of operator cab glass (stuck glass)…..4630
Removal and installation of front window assembly…..4640
Removal and installation of floor frame assembly…..4647
Electrical system…..4652
Removal and installation of air conditioner unit assembly…..4653
Removal and installation of KOMTRAX communication modem assembly…..4656
Removal and installation of monitor assembly…..4657
Removal and installation of pump controller assembly…..4659
Removal and installation of engine controller…..4661
90 Diagrams and drawings…..0
Hydraulic diagrams and drawings…..4664
Hydraulic circuit diagram…..4666
Electrical diagrams and drawings…..4669
Electrical circuit diagram…..4671
Connector list and stereogram…..4676
SEN02223-12 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Shop Manual…..4679
COVER…..4679
00 Index and foreword…..0
Index…..4681
Composition of shop manual…..4682
Table of contents…..4684
Foreword and general information…..4693
Safety notice…..4694
How to read the shop manual…..4699
Explanation of terms for maintenance standard…..4701
Handling of electric equipment and hydraulic component…..4703
Handling of connectors newly used for engines…..4712
How to read electric wire code…..4715
Precautions when carrying out operation…..4718
Method of disassembling and connecting push-pull type coupler…..4721
Standard tightening torque table…..4724
Conversion table…..4728
01 Specification…..0
Specification and technical data…..4735
Specification dimension drawings…..4736
Specifications…..4738
Weight table…..4742
Table of fuel, coolant and lubricants…..4746
10 Structure, function and maintenance standard…..0
Engine and cooling system…..4749
Engine related parts…..4750
Radiator, oil cooler and aftercooler…..4751
Power train…..4753
Power train…..4754
Swing circle…..4755
Swing machinery…..4756
Final drive…..4758
Sprocket…..4760
Undercarriage and frame…..4763
Track frame and recoil spring…..4764
Idler…..4766
Carrier roller…..4768
Track roller…..4769
Track shoe…..4770
Hydraulic system, Part 1…..4775
Hydraulic equipment layout drawing…..4776
Hydraulic tank and filter…..4778
Hydraulic pump…..4780
Hydraulic system, Part 2…..4805
Control valve…..4806
CLSS…..4818
Functions and operation by valve…..4822
Merge-divider valve…..4837
Attachment circuit selector valve…..4862
Holding valve…..4864
Hydraulic system, Part 3…..4871
Valve control…..4872
PPC valve…..4874
Solenoid valve…..4890
PPC accumulator…..4892
Return oil filter…..4893
Center swivel joint…..4894
Travel motor…..4895
Swing motor…..4907
Hydraulic cylinder…..4916
Work equipment…..4919
Work equipment…..4920
Dimensions of components…..4922
Cab and its attachments…..4927
Air conditioner piping…..4928
Electrical system…..4931
Engine control…..4932
Electrical control system…..4943
Monitor system…..4968
Sensors…..4995
KOMTRAX terminal system…..4998
20 Standard value table…..0
Standard service value table…..5001
Standard value table for engine…..5002
Standard value table for chassis related parts…..5003
Standard value table for chassis related parts (Loading shovel specification)…..5012
30 Testing and adjusting…..0
Testing and adjusting, Part 1…..5023
Tools for testing, adjusting and troubleshooting…..5025
Sketches of special tools…..5029
Testing engine speed…..5030
Testing air boost pressure…..5031
Testing exhaust temperature…..5032
Testing exhaust gas color…..5033
Adjusting valve clearance…..5034
Testing compression pressure…..5036
Testing blow-by pressure…..5038
Testing engine oil pressure…..5039
Testing EGR valve drive pressure…..5040
Handling fuel system parts…..5041
Releasing residual pressure from fuel system…..5041
Testing fuel pressure…..5042
Handling during cylinder cut-out operation…..5043
Handling during no injection cranking operation…..5043
Testing fuel return and leakage…..5044
Bleeding air from fuel circuit…..5047
Checking fuel circuit for leakage…..5049
Checking and adjusting fan belt and alternator belt…..5050
Checking and adjusting air conditioner compressor belt tension…..5051
Testing swing circle bearing clearance…..5052
Checking and adjusting track shoe tension…..5053
Testing and adjustment oil pressure in work equipment, swing, and travel circuits…..5054
Testing control circuit basic pressure…..5058
Checking and adjusting pump PC control circuit oil pressure…..5059
Checking and adjusting pump LS control circuit oil pressure…..5062
Testing solenoid valve output pressure…..5067
Testing PPC valve output pressure…..5070
Adjusting play of work equipment and swing PPC valves…..5072
Inspecting locations of hydraulic drift of work equipment…..5073
Releasing residual pressure from hydraulic circuit…..5075
Testing oil leakage amount…..5076
Bleeding air from various parts…..5079
Testing and adjusting, Part 2…..5083
Special functions of machine monitor…..5084
Testing and adjusting, Part 3…..5139
Handling voltage circuit of engine controller…..5140
Preparation work for troubleshooting of electrical system…..5141
Procedure for testing diodes…..5146
Pm Clinic service…..5147
Undercarriage troubleshooting report…..5154
40 Troubleshooting…..0
Failure code table and fuse locations…..5157
Failure code table…..5158
Fuse locations…..5161
General Information on troubleshooting…..5167
Points to remember when troubleshooting…..5168
Sequence of events in troubleshooting…..5169
Check before troubleshooting…..5170
Classification and troubleshooting steps…..5171
Information in troubleshooting table…..5172
Possible problems and troubleshooting No…..5174
Connection table for connector pin numbers…..5176
T- branch box and T- branch adapter table…..5212
Troubleshooting by failure code, Part 1…..5217
Failure code [989L00] Engine Controller Lock Caution 1…..5219
Failure code [989M00] Engine Controller Lock Caution 2…..5220
Failure code [989N00] Engine Controller Lock Caution 3…..5221
Failure code [AA10NX] Air cleaner Clogging…..5222
Failure code [AB00KE] Charge Voltage Low…..5224
Failure code [B@BAZG] Eng Oil Press Low…..5226
Failure code [B@BAZK] Eng Oil Level Low…..5228
Failure code [B@BCNS] Eng Water Overheat…..5230
Failure code [B@BCZK] Eng Water Level Low…..5232
Failure code [B@HANS] Hydr Oil Overheat…..5234
Failure code [CA111] EMC Critical Internal Failure…..5235
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…..5237
Failure code [CA122] Chg Air Press Sensor High Error…..5238
Failure code [CA123] Chg Air Press Sensor Low Error…..5240
Failure code [CA131] Throttle Sensor High Error…..5242
Failure code [CA132] Throttle Sensor Low Error…..5244
Failure code [CA135] Eng Oil Press Sensor High Error…..5246
Failure code [CA141] Eng Oil Press Sensor Low Error…..5248
Failure code [CA144] Coolant Temp Sensor High Error…..5249
Failure code [CA145] Coolant Temp Sensor Low Error…..5251
Failure code [CA153] Chg Air Temp Sensor High Error…..5253
Failure code [CA154] Chg Air Temp Sensor Low Error…..5255
Failure code [CA187] Sens Supply 2 Volt Low Error…..5257
Failure code [CA221] Ambient Press Sens High Error…..5259
Failure code [CA222] Ambient Press Sens Low Error…..5261
Failure code [CA227] Sens Supply 2 Volt High Error…..5263
Failure code [CA234] Eng Overspeed…..5264
Failure code [CA238] Ne Speed Sens Supply Volt Error…..5265
Failure code [CA263] Fuel Temp Sensor High Error…..5266
Failure code [CA265] Fuel Temp Sensor Low Error…..5268
Failure code [CA271] IMV/PCV1 Short Error…..5269
Failure code [CA272] IMV/PCV1 Open Error…..5271
Failure code [CA273] PCV2 Short Error…..5273
Failure code [CA274] PCV2 Open Error…..5275
Failure code [CA322] Inj #1 Open/Short Error…..5277
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error…..5279
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error…..5281
Failure code [CA325] Inj #6 Open/Short Error…..5283
Failure code [CA331] Inj #2 Open/Short Error…..5285
Failure code [CA332] Inj #4 Open/Short Error…..5287
Troubleshooting by failure code, Part 2…..5291
Failure code [CA342] Calibration Code Incompatibility…..5293
Failure code [CA351] Injectors Drive Circuit Error…..5294
Failure code [CA352] Sens Supply 1 Volt Low Error…..5296
Failure code [CA386] Sens Supply 1 Volt High Error…..5298
Failure code [CA441] Battery Voltage Low Error…..5300
Failure code [CA442] Battery Voltage High Error…..5302
Failure code [CA449] Rail Press Very High Error…..5304
Failure code [CA451] Rail Press Sensor High Error…..5307
Failure code [CA452] Rail Press Sensor Low Error…..5309
Failure code [CA553] Rail Press High Error…..5311
Failure code [CA554] Rail Press Sensor In Range Error…..5312
Failure code [CA559] Rail Press Low Error…..5313
Failure code [CA689] Eng Ne Speed Sensor Error…..5317
Failure code [CA731] Eng Bkup Speed Sens Phase Error…..5319
Failure code [CA757] All Continuous Data Lost Error…..5320
Failure code [CA778] Eng Bkup Speed Sensor Error…..5322
Failure code [CA1228] EGR valve servo error 1…..5324
Failure code [CA1625] EGR valve servo error 2…..5325
Failure code [CA1633] KOMNET Datalink Timeout Error…..5326
Failure code [CA2185] Throt Sens Sup Volt High Error…..5328
Failure code [CA2186] Throt Sens Sup Volt Low Error…..5330
Failure code [CA2249] Rail Press Very Low Error…..5331
Failure code [CA2271] EGR valve lift sensor high error…..5332
Failure code [CA2272] EGR valve lift sensor low error…..5334
Failure code [CA2351] EGR valve solenoid operation short circuit…..5335
Failure code [CA2352] EGR valve solenoid operation disconnect…..5337
Failure code [CA2555] Grid Htr Relay Volt Low Error…..5338
Failure code [CA2556] Grid Htr Relay Volt High Error…..5340
Failure code [D110KB] Battery Relay Drive S/C…..5342
Failure code [D19JKZ] Personal Code Relay Abnormality…..5344
Failure code [D862KA] GPS Antenna Discon…..5346
Failure code [DA22KK] Pump Solenoid Power Low Error…..5347
Failure code [DA25KP] 5V sensor power supply output 1 abnormality…..5349
Failure code [DA29KQ] Model Selection Abnormality…..5352
Troubleshooting by failure code, Part 3…..5355
Failure code [DA2RMC] CAN Discon (Pump con detected)…..5357
Failure code [DAF8KB] Short circuit in camera power supply…..5359
Failure code [DAFGMC] GPS Module Error…..5361
Failure code [DAFRMC] CAN discon (Monitor detected)…..5362
Failure code [DGH2KB] Hyd Oil Sensor Short…..5364
Failure code [DHPAMA] F Pump Press Sensor Abnormality…..5365
Failure code [DHPBMA] R Pump Press Sensor Abnormality…..5367
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality…..5369
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality…..5371
Failure code [DHX1MA] Overload Sensor Abnormality (Analog)…..5373
Failure code [DW43KA] Travel Speed Sol. Open Circuit…..5374
Failure code [DW43KB] Travel Speed Sol. Short Circuit…..5376
Failure code [DW45KA] Swing Brake Sol. Open Circuit…..5378
Failure code [DW45KB] Swing Brake Sol. Short Circuit…..5380
Failure code [DW91KA] Travel Junction Sol.Open Circuit…..5382
Failure code [DW91KB] Travel Junction Sol. Short Circuit…..5384
Failure code [DWA2KA] Attachment Sol Open Circuit…..5386
Failure code [DWA2KB] Attachment Sol Short Circuit…..5387
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit…..5388
Failure code [DWJ0KB] Merge-divider Sol. Short Circuit…..5390
Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit…..5392
Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit…..5394
Failure code [DXA0KA] PC-EPC Sol. Open Circuit…..5396
Failure code [DXA0KB] PC-EPC Sol. Short Circuit…..5398
Failure code [DXE0KA] LS-EPC Sol. Open Circuit…..5400
Failure code [DXE0KB] LS-EPC Sol. Short Circuit…..5402
Failure code [DXE4KA] Service Current EPC Open Circuit…..5404
Failure code [DXE4KB] Service Current EPC Short Circuit…..5405
Failure code [DY20KA] Wiper Working Abnormality…..5406
Failure code [DY20MA] Wiper Parking Abnormality…..5408
Failure code [DY2CKA] Washer Drive Open Discon…..5410
Failure code [DY2CKB] Washer Drive Short Circuit…..5412
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit…..5414
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit…..5416
Troubleshooting of electrical system (E-mode)…..5419
Before carrying out troubleshooting of electrical system…..5422
Information contained in troubleshooting table…..5424
E-1 Engine does not start…..5425
E-2 Auto-decelerator does not operate…..5428
E-3 Automatic warming-up system does not operate…..5430
E-4 Preheater does not operate…..5432
E-5 All work equipment, swing, and travel mechanism do not move…..5434
E-6 Power maximizing function does not operate…..5436
E-7 Machine monitor does not display at all…..5438
E-8 Machine monitor does not display some items…..5440
E-9 Contents of display by machine monitor are different from applicable machine…..5440
E-10 Fuel level monitor was lighted in red while engine running…..5441
E-11 Engine coolant temperature gauge does not indicate normally…..5442
E-12 Hydraulic oil temperature gauge does not indicate normally…..5444
E-13 Fuel level gauge does not indicate normally…..5445
E-14 Swing lock monitor does not indicate normally…..5446
E-15 When monitor switch is operated, monitor displays nothing…..5448
E-16 Windshield wiper and window washer do not operate…..5450
E-17 Machine push-up function does not operate normally…..5454
E-18 Monitoring function fails to display “boom raise” normally…..5456
E-19 Monitoring function fails to display “boom lower” normally…..5458
E-20 Monitoring function fails to display “arm IN” normally…..5460
E-21 Monitoring function fails to display “arm OUT” normally…..5462
E-22 Monitoring function fails to display “bucket CURL” normally…..5464
E-23 Monitoring function fails to display “bucket DUMP” normally…..5466
E-24 Monitoring function fails to display “swing” normally…..5468
E-25 Monitoring function fails to display “travel” normally…..5470
E-26 Monitoring function fails to display “travel differential pressure” normally…..5472
E-27 Monitoring function fails to display “service” normally…..5474
E-28 KOMTRAX system does not operate normally…..5476
E-29 Air conditioner does not operate…..5478
E-30 Travel alarm does not sound or does not stop sounding…..5480
E-31 Horn does not sound…..5482
Troubleshooting of hydraulic and mechanical system (H-mode)…..5485
System chart for hydraulic and mechanical system…..5488
Information contained in troubleshooting table…..5490
H-1 All work equipment lack power, or travel and swing speeds are slow…..5492
H-2 Engine speed sharply drops or engine stalls…..5494
H-3 No work equipment, swing or travel move…..5495
H-4 Abnormal noise is heard from around hydraulic pump…..5495
H-5 Auto-decelerator does not work…..5496
H-6 Fine control mode does not function or responds slow…..5496
H-7 Boom moves slowly or lacks power…..5497
H-8 Arm moves slowly or lacks power…..5498
H-9 Bucket moves slowly or lacks power…..5499
H-10 Work equipment does not move in its single operation…..5499
H-11 Work equipment has a bit too fast hydraulic drift…..5500
H-12 Work equipment has big time lag…..5502
H-13 Other work equipment moves when relieving single circuit…..5502
H-14 Power max. switch does not operate…..5502
H-15 Machine push-up function does not operate…..5503
H-16 In compound operation of work equipment, speed of part loaded more is low…..5504
H-17 When machine swings and raises boom simultaneously, boom rising speed is low…..5504
H-18 When machine swings and travels simultaneously, travel speed lowers largely…..5504
H-19 Machine deviates during travel…..5505
H-20 Travel speed is low…..5506
H-21 Machine is not steered well or steering power is low…..5507
H-22 Travel speed does not change or travel speed is low or high…..5508
H-23 Travel system does not move (only one side)…..5509
H-24 Upper structure does not swing…..5510
H-25 Swing acceleration or swing speed is low…..5512
H-26 Upper structure overruns remarkably when it stops swinging…..5514
H-27 Large shock is made when upper structure stops swinging…..5515
H-28 Large sound is made when upper structure stops swinging…..5515
H-29 Hydraulic drift of swing is large…..5516
H-30 Attachment circuit is not changed…..5517
H-31 Oil flow in attachment circuit cannot be controlled…..5517
Troubleshooting of engine (S-mode)…..5519
Method of using troubleshooting chart…..5521
S-1 Starting performance is poor…..5524
S-2 Engine does not start…..5526
S-3 Engine does not pick up smoothly…..5530
S-4 Engine stops during operations…..5531
S-5 Engine does not rotate smoothly…..5532
S-6 Engine lacks output (or lacks power)…..5533
S-7 Exhaust smoke is black (incomplete combustion)…..5534
S-8 Oil consumption is excessive (or exhaust smoke is blue)…..5535
S-9 Oil becomes contaminated quickly…..5536
S-10 Fuel consumption is excessive…..5537
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…..5538
S-12 Oil pressure drops…..5539
S-13 Oil level rises (Entry of coolant or fuel)…..5540
S-14 Coolant temperature becomes too high (overheating)…..5542
S-15 Abnormal noise is made…..5543
S-16 Vibration is excessive…..5544
50 Disassembly and assembly…..0
General information on disassembly and assembly…..5547
How to read this manual…..5548
Coating materials list…..5550
Special tool list…..5553
Sketches of special tools…..5556
Engine and cooling system…..5563
Removal and installation of fuel supply pump assembly…..5564
Removal and installation of fuel injector assembly…..5568
Removal and installation of engine front seal…..5574
Removal and installation of engine rear seal…..5577
Removal and installation of cylinder head assembly…..5582
Removal and installation of radiator assembly…..5591
Removal and installation of hydraulic oil cooler assembly…..5593
Removal and installation of aftercooler assembly…..5595
Removal and installation of engine and hydraulic oil pump assembly…..5596
Power train…..5605
Removal and installation of travel motor and final drive assembly…..5606
Disassembly and assembly of final drive assembly…..5607
Removal and installation of swing motor and swing machinery assembly…..5615
Disassembly and assembly of swing motor and swing machinery assembly…..5616
Removal and installation of swing circle assembly…..5623
Undercarriage and frame…..5625
Disassembly and assembly of carrier roller assembly…..5626
Disassembly and assembly of track roller assembly…..5628
Disassembly and assembly of idler assembly…..5629
Disassembly and assembly of recoil spring assembly…..5632
Removal and installation of sprocket…..5634
Expansion and installation of track shoe assembly…..5635
Removal and installation of revolving frame assembly…..5637
Removal and installation of counterweight assembly…..5640
Hydraulic system…..5645
Removal and installation of center swivel joint assembly…..5646
Disassembly and assembly of center swivel joint assembly…..5648
Removal and installation of hydraulic tank assembly…..5649
Removal and installation of control valve assembly…..5651
Disassembly and assembly of control valve assembly…..5654
Removal and installation of hydraulic pump assembly…..5658
Removal and installation of oil seal in hydraulic pump input shaft…..5661
Disassembly and assembly of work equipment PPC valve assembly…..5662
Disassembly and assembly of travel PPC valve assembly…..5664
Disassembly and assembly of hydraulic cylinder assembly…..5667
Work equipment…..5675
Removal and installation of work equipment assembly…..5676
Cab and its attachments…..5681
Removal and installation of operator cab assembly…..5682
Removal and installation of operator cab glass (stuck glass)…..5685
Removal and installation of front window assembly…..5695
Removal and installation of floor frame assembly…..5702
Electrical system…..5707
Removal and installation of air conditioner unit assembly…..5708
Removal and installation of KOMTRAX communication modem assembly…..5711
Removal and installation of monitor assembly…..5712
Removal and installation of pump controller assembly…..5714
Removal and installation of engine controller…..5716
90 Diagrams and drawings…..0
Hydraulic diagrams and drawings…..5719
Hydraulic circuit diagram…..5721
Electrical diagrams and drawings…..5724
Electrical circuit diagram…..5726
Connector list and stereogram…..5731
TEN00038-03 – Hydraulic Excavator PC400-7, PC400LC-7, PC450-7, PC450LC-7 Operation & Maintenance Manual…..5734
COVER…..5734
FOREWORD…..5735
FOREWORD…..5736
SAFETY INFORMATION…..5739
INTRODUCTION…..5741
DIRECTIONS OF MACHINE…..5741
BREAKING-IN THE NEW MACHINE…..5741
PRODUCT INFORMATION…..5742
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..5742
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..5742
SERVICE METER LOCATION…..5743
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..5743
CONTENTS…..5744
SAFETY…..5748
SAFETY INFORMATION…..5749
SAFETY LABELS…..5751
LOCATION OF SAFETY LABELS…..5751
SAFETY LABELS…..5752
SAFETY INFORMATION…..5757
SAFETY RULES…..5757
IF PROBLEMS ARE FOUND…..5757
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..5757
FIRE EXTINGUISHER AND FIRST AID KIT…..5757
SAFETY EQUIPMENT…..5757
KEEP MACHINE CLEAN…..5758
KEEP OPERATOR'S COMPARTMENT CLEAN…..5758
LEAVING OPERATOR'S SEAT WITH LOCK…..5758
HANDRAILS AND STEPS…..5759
PRECAUTIONS WHEN WORKING IN HIGH PLACES…..5759
MOUNTING AND DISMOUNTING…..5759
NO PERSONS ON ATTACHMENTS…..5759
DO NOT GET CAUGHT IN ARTICULATED PORTION…..5760
BURN PREVENTION…..5760
FIRE PREVENTION AND EXPLOSION PREVENTION…..5761
ACTION IF FIRE OCCURS…..5762
WINDSHIELD WASHER FLUID…..5762
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..5762
ATTACHMENT INSTALLATION…..5762
ATTACHMENT COMBINATIONS…..5762
CAB WINDOW GLASSES…..5762
UNAUTHORIZED MODIFICATIONS…..5763
SAFETY AT JOBSITE…..5763
WORKING ON LOOSE GROUND…..5763
DISTANCE TO HIGH VOLTAGE CABLES…..5764
ENSURE GOOD VISIBILITY…..5764
VENTILATION FOR ENCLOSED AREA…..5765
SIGNALMAN'S SIGNAL AND SIGNS…..5765
EMERGENCY EXIT FROM OPERATOR'S CAB…..5765
ASBESTOS DUST HAZARD PREVENTION…..5765
SAFETY MACHINE OPERATION…..5766
STARTING ENGINE…..5766
CHECKS BEFORE STARTING ENGINE…..5766
SAFETY RULES FOR STARTING ENGINE…..5767
STARTING ENGINE IN COLD WEATHER…..5767
OPERATION…..5768
CHECKS BEFORE OPERATION…..5768
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..5768
SAFETY RULES FOR TRAVELING…..5769
TRAVELING ON SLOPES…..5769
OPERATIONS ON SLOPES…..5770
PROHIBITED OPERATIONS…..5770
OPERATIONS ON SNOW…..5772
PARKING MACHINE…..5773
TRANSPORTATION…..5774
LOADING AND UNLOADING…..5774
SHIPPING THE MACHINE…..5774
BATTERY…..5775
BATTERY HAZARD PREVENTION…..5775
STARTING ENGINE WITH BOOSTER CABLES…..5776
TOWING…..5777
SAFETY RULES FOR TOWING…..5777
LIFTING OBJECTS WITH BUCKET…..5778
SAFETY RULES FOR LIFTING OBJECTS…..5778
SAFETY MAINTENANCE INFORMATION…..5779
WARNING TAG…..5779
KEEP WORK PLACE CLEAN AND TIDY…..5779
APPOINT LEADER WHEN WORKING WITH OTHERS…..5779
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..5780
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..5781
PROPER TOOLS…..5781
ACCUMULATOR, GAS SPRING…..5782
PERSONNEL…..5782
ATTACHMENTS…..5782
WORK UNDER THE MACHINE…..5782
NOISE…..5782
WHEN USING HAMMER…..5783
WELDING WORKS…..5783
REMOVING BATTERY TERMINALS…..5783
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..5783
DO NOT DISASSEMBLE RECOIL SPRINGS…..5783
SAFETY RULES FOR HIGH-PRESSURE OIL…..5784
SAFETY HANDLING HIGH-PRESSURE HOSES…..5784
WASTE MATERIALS…..5784
AIR CONDITIONER MAINTENANCE…..5784
COMPRESSED AIR…..5785
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..5785
OPERATION…..5786
MACHINE VIEW ILLUSTRATIONS…..5787
OVERALL MACHINE VIEW…..5787
CONTROLS AND GAUGES…..5788
DETAILED CONTROLS AND GAUGES…..5790
MONITORING SYSTEM…..5790
SWITCHES…..5815
CONTROL LEVERS AND PEDALS…..5820
SUN ROOF…..5823
WINDSHIELD…..5823
EMERGENCY EXIT FROM OPERATOR'S CAB…..5828
DOOR LOCK…..5828
CAP WITH LOCK…..5829
HOT AND COOL BOX…..5830
MAGAZINE BOX…..5831
ASHTRAY…..5831
AIR CONDITIONER CONTROLS…..5832
RADIO…..5846
AUXILIARY ELECTRIC POWER…..5851
FUSE…..5852
FUSIBLE LINK…..5853
CONTROLLER…..5853
TOOL BOX…..5854
GREASE GUN HOLDER…..5854
ACCUMULATOR…..5855
MACHINE OPERATIONS AND CONTROLS…..5856
BEFORE STARTING ENGINE…..5856
STARTING ENGINE…..5871
AFTER STARTING ENGINE…..5875
STOPPING THE ENGINE…..5884
MACHINE OPERATION…..5885
STEERING THE MACHINE…..5889
SWINGING…..5891
WORK EQUIPMENT CONTROLS AND OPERATIONS…..5892
WORKING MODE…..5894
PROHIBITED OPERATIONS…..5895
GENERAL OPERATION INFORMATION…..5897
TRAVELING ON SLOPES…..5899
ESCAPE FROM MUD…..5901
RECOMMENDED APPLICATIONS…..5902
BUCKET REPLACEMENT AND INVERSION…..5904
PARKING MACHINE…..5907
CHECK AFTER SHUT OFF ENGINE…..5908
MACHINE INSPECTION AFTER DAILY WORK…..5908
LOCKING…..5909
TRANSPORTATION…..5910
PRECAUTIONS FOR TRANSPORTATION…..5910
LOADING AND UNLOADING WITH TRAILER…..5911
LIFTING MACHINE…..5919
TRANSPORTATION POSTURE…..5921
COLD WEATHER OPERATION…..5924
COLD WEATHER OPERATION INFORMATION…..5924
AFTER DAILY WORK COMPLETION…..5927
AFTER COLD WEATHER SEASON…..5927
LONG TERM STORAGE…..5928
BEFORE STORAGE…..5928
DURING STORAGE…..5928
AFTER STORAGE…..5928
STARTING MACHINE AFTER LONG-TERM STORAGE…..5929
TROUBLES AND ACTIONS…..5930
RUNNING OUT OF FUEL…..5930
PHENOMENA THAT ARE NOT FAILURES…..5931
TOWING THE MACHINE…..5932
LIGHTWEIGHT TOWING HOLE…..5933
SEVERE JOB CONDITION…..5933
DISCHARGED BATTERY…..5934
OTHER TROUBLE…..5938
MAINTENANCE…..5944
MAINTENANCE INFORMATION…..5945
OUTLINE OF SERVICE…..5947
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..5947
ELECTRIC SYSTEM MAINTENANCE…..5950
WEAR PARTS…..5951
WEAR PARTS LIST…..5951
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…..5952
TIGHTENING TORQUE SPECIFICATIONS…..5956
TIGHTENING TORQUE LIST…..5956
SAFETY CRITICAL PARTS…..5957
SAFETY CRITICAL PARTS LIST…..5957
MAINTENANCE SCHEDULE…..5958
MAINTENANCE SCHEDULE CHART…..5958
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..5960
MAINTENANCE PROCEDURE…..5961
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..5961
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…..5961
WHEN REQUIRED…..5962
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..5962
CLEAN INSIDE OF COOLING SYSTEM…..5967
CHECK AND TIGHTEN TRACK SHOE BOLTS…..5969
CHECK AND ADJUST TRACK TENSION…..5970
CHECK ELECTRICAL INTAKE AIR HEATER…..5971
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..5972
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..5975
REPLACE BUCKET SIDE CUTTER, SHROUD…..5976
ADJUST BUCKET CLEARANCE…..5977
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..5978
CHECK AND MAINTENANCE AIR CONDITIONER…..5979
WASH WASHABLE FLOOR…..5980
BLEEDING AIR FROM HYDRAULIC SYSTEM…..5983
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..5985
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)…..5986
CHECK BEFORE STARTING…..5987
EVERY 50 HOURS MAINTENANCE…..5988
LUBRICATING…..5988
EVERY 250 HOURS MAINTENANCE…..5989
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…..5989
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..5990
CHECK LEVEL OF BATTERY ELECTROLYTE…..5991
LUBRICATE SWING CIRCLE (2 POINTS)…..5994
CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST…..5994
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..5995
EVERY 500 HOURS MAINTENANCE…..5996
LUBRICATING…..5996
REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITHOUT ADDITIONAL FUEL FILTER CARTRIDGE)…..5998
CHECK, WASH FUEL STRAINER…..6000
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..6001
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..6002
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER …..6004
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…..6005
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…..6006
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED WITH MACHINES)…..6007
EVERY 1000 HOURS MAINTENANCE…..6009
REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITH ADDITIONAL FUEL FILTER CARTRIDGE)…..6009
REPLACE HYDRAULIC OIL FILTER ELEMENT…..6011
CHANGE OIL IN SWING MACHINERY CASE…..6012
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…..6013
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..6013
CHECK PLAY TURBOCHARGER ROTOR…..6013
REPLACE CORROSION RESISTOR CARTRIDGE…..6014
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT…..6015
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)…..6015
EVERY 2000 HOURS MAINTENANCE…..6016
CHANGE OIL IN FINAL DRIVE CASE…..6016
CHECK INJECTOR…..6016
CLEAN HYDRAULIC TANK STRAINER…..6017
CLEAN ENGINE BREATHER…..6017
CLEAN, CHECK TURBOCHARGER…..6018
CHECK ALTERNATOR, STARTING MOTOR…..6018
CHECK ENGINE VALVE CLEARANCE, ADJUST…..6018
CHECK VIBRATION DAMPER…..6018
EVERY 4000 HOURS MAINTENANCE…..6019
CHECK WATER PUMP…..6019
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER…..6019
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..6020
REPLACE INJECTOR NOZZLE ASSEMBLY…..6020
EVERY 5000 HOURS MAINTENANCE…..6021
CHANGE OIL IN HYDRAULIC TANK…..6021
EVERY 8000 HOURS MAINTENANCE…..6023
REPLACE HIGH-PRESSURE PIPING CLAMP…..6023
REPLACE FUEL SPRAY PREVENTION CAP…..6023
SPECIFICATIONS…..6024
SPECIFICATIONS…..6025
ATTACHMENTS, OPTIONS…..6028
GENERAL PRECAUTIONS FOR SAFETY…..6029
PRECAUTIONS WHEN SELECTING…..6029
READ THE INSTRUCTION MANUAL THOROUGHLY…..6029
PRECAUTIONS WHEN REMOVING OR INSTALLING…..6029
PRECAUTIONS WHEN USING…..6029
MACHINE READY FOR ATTACHMENT…..6030
LOCATIONS…..6030
HYDRAULIC CIRCUIT…..6034
ATTACHMENT REMOVAL AND INSTALLATION…..6038
ATTACHMENT OPERATIONS…..6040
LONG TERM STORAGE…..6042
SPECIFICATIONS…..6042
ATTACHMENT GUIDE…..6043
ATTACHMENT COMBINATIONS…..6043
RECOMMENDED ATTACHMENT OPERATIONS…..6045
HYDRAULIC BREAKER…..6045
LOADING SHOVEL…..6049
EXPLANATION OF COMPONENTS…..6050
SWITCHES…..6050
OPERATIONS…..6053
OPERATION OF WORK EQUIPMENT…..6053
PRECAUTIONS DURING OPERATION…..6055
EXCAVATOR WORK…..6059
PRECAUTIONS WHEN DISASSEMBLING MACHINE…..6060
RELEASING PRESSURE…..6060
TRANSPORTATION…..6061
MACHINE CONFIGURATION FOR TRANSPORT…..6061
MAINTENANCE…..6065
CHECK BEFORE STARTING…..6065
EVERY 10 HOURS MAINTENANCE…..6066
SPECIFICATION…..6067
COMBINATION OF WORK EQUIPMENT…..6069
COMBINATION OF WORK EQUIPMENT…..6069
INDEX…..6071
TEN00039-03 – Hydraulic Excavator GALEO PC400-7, PC400LC-7, PC450-7, PC450LC-7 Operation & Maintenance Manual…..6074
COVER…..6074
FOREWORD…..6076
FOREWORD…..6077
SAFETY INFORMATION…..6080
INTRODUCTION…..6082
DIRECTIONS OF MACHINE…..6082
BREAKING-IN THE NEW MACHINE…..6082
PRODUCT INFORMATION…..6083
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..6083
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..6083
SERVICE METER LOCATION…..6084
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..6084
CONTENTS…..6085
SAFETY…..6090
SAFETY INFORMATION…..6091
SAFETY LABELS…..6093
LOCATION OF SAFETY LABELS…..6093
SAFETY LABELS…..6094
SAFETY INFORMATION…..6099
SAFETY RULES…..6099
IF PROBLEMS ARE FOUND…..6099
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..6099
FIRE EXTINGUISHER AND FIRST AID KIT…..6099
SAFETY EQUIPMENT…..6099
KEEP MACHINE CLEAN…..6100
KEEP OPERATOR'S COMPARTMENT CLEAN…..6100
LEAVING OPERATOR'S SEAT WITH LOCK…..6100
HANDRAILS AND STEPS…..6101
PRECAUTIONS WHEN WORKING IN HIGH PLACES…..6101
MOUNTING AND DISMOUNTING…..6101
NO PERSONS ON ATTACHMENTS…..6101
DO NOT GET CAUGHT IN ARTICULATED PORTION…..6102
BURN PREVENTION…..6102
FIRE PREVENTION AND EXPLOSION PREVENTION…..6103
ACTION IF FIRE OCCURS…..6104
WINDSHIELD WASHER FLUID…..6104
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..6104
ATTACHMENT INSTALLATION…..6104
ATTACHMENT COMBINATIONS…..6104
CAB WINDOW GLASSES…..6104
UNAUTHORIZED MODIFICATIONS…..6105
SAFETY AT JOBSITE…..6105
WORKING ON LOOSE GROUND…..6105
DISTANCE TO HIGH VOLTAGE CABLES…..6106
ENSURE GOOD VISIBILITY…..6106
VENTILATION FOR ENCLOSED AREA…..6107
SIGNALMAN'S SIGNAL AND SIGNS…..6107
EMERGENCY EXIT FROM OPERATOR'S CAB…..6107
ASBESTOS DUST HAZARD PREVENTION…..6107
SAFETY MACHINE OPERATION…..6108
STARTING ENGINE…..6108
CHECKS BEFORE STARTING ENGINE…..6108
SAFETY RULES FOR STARTING ENGINE…..6109
STARTING ENGINE IN COLD WEATHER…..6109
OPERATION…..6110
CHECKS BEFORE OPERATION…..6110
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..6110
SAFETY RULES FOR TRAVELING…..6111
TRAVELING ON SLOPES…..6111
OPERATIONS ON SLOPES…..6112
PROHIBITED OPERATIONS…..6112
OPERATIONS ON SNOW…..6114
PARKING MACHINE…..6115
TRANSPORTATION…..6116
LOADING AND UNLOADING…..6116
SHIPPING THE MACHINE…..6116
BATTERY…..6117
BATTERY HAZARD PREVENTION…..6117
STARTING ENGINE WITH BOOSTER CABLES…..6118
TOWING…..6119
SAFETY RULES FOR TOWING…..6119
LIFTING OBJECTS WITH BUCKET…..6120
SAFETY RULES FOR LIFTING OBJECTS…..6120
SAFETY MAINTENANCE INFORMATION…..6121
WARNING TAG…..6121
KEEP WORK PLACE CLEAN AND TIDY…..6121
APPOINT LEADER WHEN WORKING WITH OTHERS…..6121
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..6122
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..6123
PROPER TOOLS…..6123
ACCUMULATOR, GAS SPRING…..6124
PERSONNEL…..6124
ATTACHMENTS…..6124
WORK UNDER THE MACHINE…..6124
NOISE…..6124
WHEN USING HAMMER…..6125
WELDING WORKS…..6125
REMOVING BATTERY TERMINALS…..6125
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..6125
DO NOT DISASSEMBLE RECOIL SPRINGS…..6125
SAFETY RULES FOR HIGH-PRESSURE OIL…..6126
SAFETY HANDLING HIGH-PRESSURE HOSES…..6126
WASTE MATERIALS…..6126
AIR CONDITIONER MAINTENANCE…..6126
COMPRESSED AIR…..6127
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..6127
OPERATION…..6128
MACHINE VIEW ILLUSTRATIONS…..6129
OVERALL MACHINE VIEW…..6129
CONTROLS AND GAUGES…..6130
DETAILED CONTROLS AND GAUGES…..6131
MONITORING SYSTEM…..6131
SWITCHES…..6144
CONTROL LEVERS AND PEDALS…..6149
SUN ROOF…..6152
WINDSHIELD…..6152
EMERGENCY EXIT FROM OPERATOR'S CAB…..6157
DOOR LOCK…..6157
CAP WITH LOCK…..6158
HOT AND COOL BOX…..6159
MAGAZINE BOX…..6160
ASHTRAY…..6160
AIR CONDITIONER CONTROLS…..6161
RADIO…..6175
AUXILIARY ELECTRIC POWER…..6180
FUSE…..6181
FUSIBLE LINK…..6182
CONTROLLER…..6182
TOOL BOX…..6183
GREASE GUN HOLDER…..6183
ACCUMULATOR…..6184
MACHINE OPERATIONS AND CONTROLS…..6185
BEFORE STARTING ENGINE…..6185
STARTING ENGINE…..6199
AFTER STARTING ENGINE…..6203
STOPPING THE ENGINE…..6210
MACHINE OPERATION…..6211
STEERING THE MACHINE…..6215
SWINGING…..6217
WORK EQUIPMENT CONTROLS AND OPERATIONS…..6218
WORKING MODE…..6220
PROHIBITED OPERATIONS…..6221
GENERAL OPERATION INFORMATION…..6223
TRAVELING ON SLOPES…..6225
ESCAPE FROM MUD…..6227
RECOMMENDED APPLICATIONS…..6228
BUCKET REPLACEMENT AND INVERSION…..6230
PARKING MACHINE…..6233
CHECK AFTER SHUT OFF ENGINE…..6234
MACHINE INSPECTION AFTER DAILY WORK…..6234
LOCKING…..6235
TRANSPORTATION…..6236
PRECAUTIONS FOR TRANSPORTATION…..6236
LOADING AND UNLOADING WITH TRAILER…..6237
LIFTING MACHINE…..6245
PRECAUTIONS WHEN LOADING…..6247
TRANSPORTATION POSTURE…..6248
COLD WEATHER OPERATION…..6251
COLD WEATHER OPERATION INFORMATION…..6251
AFTER DAILY WORK COMPLETION…..6253
AFTER COLD WEATHER SEASON…..6253
LONG TERM STORAGE…..6254
BEFORE STORAGE…..6254
DURING STORAGE…..6254
AFTER STORAGE…..6254
STARTING MACHINE AFTER LONG-TERM STORAGE…..6255
TROUBLES AND ACTIONS…..6256
RUNNING OUT OF FUEL…..6256
PHENOMENA THAT ARE NOT FAILURES…..6257
TOWING THE MACHINE…..6258
LIGHTWEIGHT TOWING HOLE…..6259
SEVERE JOB CONDITION…..6259
DISCHARGED BATTERY…..6260
OTHER TROUBLE…..6264
MAINTENANCE…..6270
MAINTENANCE INFORMATION…..6271
OUTLINE OF SERVICE…..6273
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..6273
ELECTRIC SYSTEM MAINTENANCE…..6276
WEAR PARTS…..6277
WEAR PARTS LIST…..6277
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…..6278
TIGHTENING TORQUE SPECIFICATIONS…..6282
TIGHTENING TORQUE LIST…..6282
SAFETY CRITICAL PARTS…..6283
SAFETY CRITICAL PARTS LIST…..6283
MAINTENANCE SCHEDULE…..6284
MAINTENANCE SCHEDULE CHART…..6284
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..6286
MAINTENANCE PROCEDURE…..6287
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..6287
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…..6287
WHEN REQUIRED…..6288
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..6288
CLEAN INSIDE OF COOLING SYSTEM…..6293
CHECK AND TIGHTEN TRACK SHOE BOLTS…..6295
CHECK AND ADJUST TRACK TENSION…..6296
CHECK ELECTRICAL INTAKE AIR HEATER…..6297
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..6298
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..6301
REPLACE BUCKET SIDE CUTTER, SHROUD…..6302
ADJUST BUCKET CLEARANCE…..6303
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..6304
CHECK AND MAINTENANCE AIR CONDITIONER…..6305
WASH WASHABLE FLOOR…..6306
BLEEDING AIR FROM HYDRAULIC SYSTEM…..6309
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..6311
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)…..6312
CHECK BEFORE STARTING…..6313
EVERY 50 HOURS MAINTENANCE…..6314
LUBRICATING…..6314
EVERY 100 HOURS MAINTENANCE…..6315
LUBRICATING…..6315
EVERY 250 HOURS MAINTENANCE…..6317
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…..6317
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..6318
CHECK LEVEL OF BATTERY ELECTROLYTE…..6319
LUBRICATE SWING CIRCLE…..6322
CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST…..6322
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..6323
EVERY 500 HOURS MAINTENANCE…..6324
REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITHOUT ADDITIONAL FUEL FILTER CARTRIDGE)…..6324
CHECK, WASH FUEL STRAINER…..6326
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..6327
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..6328
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)…..6330
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…..6331
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…..6332
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED WITH MACHINES)…..6333
EVERY 1000 HOURS MAINTENANCE…..6335
REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITH ADDITIONAL FUEL FILTER CARTRIDGE)…..6335
REPLACE HYDRAULIC OIL FILTER ELEMENT…..6337
CHANGE OIL IN SWING MACHINERY CASE…..6338
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…..6339
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..6339
CHECK PLAY TURBOCHARGER ROTOR…..6339
REPLACE CORROSION RESISTOR CARTRIDGE…..6340
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT…..6341
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)…..6341
EVERY 2000 HOURS MAINTENANCE…..6342
CHANGE OIL IN FINAL DRIVE CASE…..6342
CHECK INJECTOR…..6342
CLEAN HYDRAULIC TANK STRAINER…..6343
CLEAN ENGINE BREATHER…..6343
CLEAN, CHECK TURBOCHARGER…..6344
CHECK ALTERNATOR, STARTING MOTOR…..6344
CHECK ENGINE VALVE CLEARANCE, ADJUST…..6344
CHECK VIBRATION DAMPER…..6344
EVERY 4000 HOURS MAINTENANCE…..6345
CHECK WATER PUMP…..6345
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER…..6345
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..6346
REPLACE INJECTOR NOZZLE ASSEMBLY…..6346
EVERY 5000 HOURS MAINTENANCE…..6347
CHANGE OIL IN HYDRAULIC TANK…..6347
EVERY 8000 HOURS MAINTENANCE…..6349
REPLACE HIGH-PRESSURE PIPING CLAMP…..6349
REPLACE FUEL SPRAY PREVENTION CAP…..6349
SPECIFICATIONS…..6350
SPECIFICATIONS…..6351
ATTACHMENTS, OPTIONS…..6354
GENERAL PRECAUTIONS FOR SAFETY…..6355
PRECAUTIONS WHEN SELECTING…..6355
READ THE INSTRUCTION MANUAL THOROUGHLY…..6355
PRECAUTIONS WHEN REMOVING OR INSTALLING…..6355
PRECAUTIONS WHEN USING…..6355
MACHINE READY FOR ATTACHMENT…..6356
LOCATIONS…..6356
HYDRAULIC CIRCUIT…..6360
ATTACHMENT REMOVAL AND INSTALLATION…..6364
ATTACHMENT OPERATIONS…..6366
LONG TERM STORAGE…..6367
SPECIFICATIONS…..6367
ATTACHMENT GUIDE…..6368
ATTACHMENT COMBINATIONS…..6368
RECOMMENDED ATTACHMENT OPERATIONS…..6370
HYDRAULIC BREAKER…..6370
MULTI-MONITOR SPECIFICATION…..6374
CONTENTS…..6375
OPERATION…..0
MACHINE VIEW ILLUSTRATIONS…..6376
CONTROLS AND GAUGES…..6376
DETAILED CONTROLS AND GAUGES…..6378
MONITORING SYSTEM…..6378
MACHINE OPERATIONS AND CONTROLS…..6403
BEFORE STARTING ENGINE…..6403
STARTING ENGINE…..6406
AFTER STARTING ENGINE…..6410
MACHINE OPERATION…..6419
SWINGING…..6422
WORKING MODE…..6423
GENERAL OPERATION INFORMATION…..6424
CHECK AFTER SHUT OFF ENGINE…..6425
MACHINE INSPECTION AFTER DAILY WORK…..6425
COLD WEATHER OPERATION…..6426
MONITOR…..6426
MAINTENANCE…..0
MAINTENANCE PROCEDURE…..6427
WHEN REQUIRED…..6427
ATTACHMENTS AND OPTIONS…..0
MACHINE READY FOR ATTACHMENT…..6432
ATTACHMENT OPERATIONS…..6432
INDEX…..6434
TEN00184-03 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Operation & Maintenance Manual…..6438
COVER…..6438
FOREWORD…..6439
BEFORE READING THIS MANU…..6440
SAFETY INFORMATION…..6441
INTRODUCTION…..6442
USE OF MACHINE…..6442
DIRECTIONS OF MACHINE…..6442
VISIBILITY FROM OPERATOR'S SEAT…..6443
PRODUCT INFORMATION…..6445
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..6445
EPA REGULATIONS, ENGINE NUMBER PLATE…..6445
SERVICE METER LOCATION…..6446
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..6446
CONTENTS…..6447
SAFETY…..6451
SAFETY…..6452
SAFETY LABELS…..6455
LOCATION OF SAFETY LABELS…..6455
SAFETY LABELS…..6456
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..6462
PRECAUTIONS BEFORE STARTING OPERATION…..6462
PREPARATIONS FOR SAFE OPERATION…..6462
FIRE PREVENTION…..6464
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..6465
DO NOT GET CAUGHT IN WORK EQUIPMENT…..6467
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..6467
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…..6467
UNAUTHORIZED MODIFICATION…..6468
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..6468
PRECAUTIONS RELATED TO CAB GLASS…..6468
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..6468
PRECAUTIONS FOR OPERATION…..6469
PRECAUTIONS FOR JOBSITE…..6469
STARTING ENGINE…..6471
OPERATION…..6473
TRANSPORTATION…..6481
TOWING…..6482
LIFTING OBJECTS WITH BUCKET…..6483
PRECAUTIONS FOR MAINTENANCE…..6484
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..6484
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..6488
OPERATION…..6495
MACHINE VIEW ILLUSTRATIONS…..6496
OVERALL MACHINE VIEW…..6496
CONTROLS AND GAUGES…..6497
DETAILED CONTROLS AND GAUGES…..6499
MONITORING SYSTEM…..6499
SWITCHES…..6564
CONTROL LEVERS AND PEDALS…..6569
SUN ROOF…..6572
WINDSHIELD…..6572
EMERGENCY ESCAPE HAMMER…..6578
DOOR LOCK…..6578
CAP WITH LOCK…..6579
DRINK BOX…..6581
MAGAZINE BOX…..6581
ASHTRAY…..6581
AIR CONDITIONER CONTROLS…..6582
RADIO…..6595
AUXILIARY ELECTRIC POWER…..6600
FUSE…..6601
FUSIBLE LINK…..6602
CONTROLLER…..6602
TOOL BOX…..6603
GREASE PUMP HOLDER…..6603
FIRE EXTINGUISHER…..6603
MACHINE OPERATIONS AND CONTROLS…..6604
BEFORE STARTING ENGINE…..6604
STARTING ENGINE…..6623
AFTER STARTING ENGINE…..6626
STOPPING THE ENGINE…..6637
MACHINE OPERATION…..6638
STEERING THE MACHINE…..6642
SWINGING…..6644
WORK EQUIPMENT CONTROLS AND OPERATIONS…..6645
WORKING MODE…..6647
PROHIBITED OPERATIONS…..6649
GENERAL OPERATION INFORMATION…..6654
TRAVELING ON SLOPES…..6656
ESCAPE FROM MUD…..6658
RECOMMENDED APPLICATIONS…..6659
BUCKET REPLACEMENT AND INVERSION…..6661
PARKING MACHINE…..6665
MACHINE INSPECTION AFTER DAILY WORK…..6666
LOCKING…..6667
TRANSPORTATION…..6668
TRANSPORTATION PROCEDURE…..6668
LOADING AND UNLOADING WITH TRAILER…..6669
LIFTING MACHINE…..6678
TRANSPORTATION POSTURE…..6680
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..6683
COLD WEATHER OPERATION…..6685
COLD WEATHER OPERATION INFORMATION…..6685
AFTER DAILY WORK COMPLETION…..6687
AFTER COLD WEATHER SEASON…..6687
LONG TERM STORAGE…..6688
BEFORE STORAGE…..6688
DURING STORAGE…..6688
AFTER STORAGE…..6689
STARTING MACHINE AFTER LONG-TERM STORAGE…..6689
TROUBLES AND ACTIONS…..6690
RUNNING OUT OF FUEL…..6690
PHENOMENA THAT ARE NOT FAILURES…..6691
TOWING THE MACHINE…..6692
LIGHTWEIGHT TOWING HOLE…..6693
SEVERE JOB CONDITION…..6693
DISCHARGED BATTERY…..6694
OTHER TROUBLE…..6698
MAINTENANCE…..6705
MAINTENANCE INFORMATION…..6706
OUTLINE OF SERVICE…..6708
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..6708
ELECTRIC SYSTEM MAINTENANCE…..6711
WEAR PARTS…..6712
WEAR PARTS LIST…..6712
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..6713
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..6715
TIGHTENING TORQUE SPECIFICATIONS…..6716
TIGHTENING TORQUE LIST…..6716
SAFETY CRITICAL PARTS…..6717
SAFETY CRITICAL PARTS LIST…..6718
MAINTENANCE SCHEDULE…..6719
MAINTENANCE SCHEDULE CHART…..6719
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..6721
MAINTENANCE PROCEDURE…..6722
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…..6722
WHEN REQUIRED…..6723
CHECK BEFORE STARTING…..6751
EVERY 50 HOURS MAINTENANCE…..6752
EVERY 250 HOURS MAINTENANCE…..6753
EVERY 500 HOURS MAINTENANCE…..6758
EVERY 1000 HOURS MAINTENANCE…..6771
EVERY 2000 HOURS MAINTENANCE…..6779
EVERY 4000 HOURS MAINTENANCE…..6786
EVERY 5000 HOURS MAINTENANCE…..6788
EVERY 8000 HOURS MAINTENANCE…..6790
SPECIFICATIONS…..6791
SPECIFICATIONS…..6792
ATTACHMENTS, OPTIONS…..6795
GENERAL PRECAUTIONS FOR SAFETY…..6796
PRECAUTIONS WHEN SELECTING…..6796
READ THE INSTRUCTION MANUAL THOROUGHLY…..6796
PRECAUTIONS WHEN REMOVING OR INSTALLING…..6796
PRECAUTIONS WHEN USING…..6796
BUCKET WITH HOOK…..6797
HOOK CONDITION…..6797
PROHIBITED OPERATIONS…..6797
MACHINE READY FOR ATTACHMENT…..6798
LOCATIONS…..6798
HYDRAULIC CIRCUIT…..6802
ATTACHMENT REMOVAL AND INSTALLATION…..6807
ATTACHMENT OPERATIONS…..6811
LONG TERM STORAGE…..6812
SPECIFICATIONS…..6812
HANDLING THE ELECTRIC PRIMING PUMP…..6813
BLEEDING AIR FROM FUEL CIRCUIT…..6813
ATTACHMENT GUIDE…..6816
ATTACHMENT COMBINATIONS…..6816
TRACK SHOES SELECTION…..6818
RECOMMENDED ATTACHMENT OPERATIONS…..6819
HYDRAULIC BREAKER…..6819
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..6823
BASIC PRECAUTIONS…..6823
INDEX…..6825
TEN00336-01 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Operation & Maintenance Manual…..6829
COVER…..6829
FOREWORD…..6830
BEFORE READING THIS MANUAL…..6831
SAFETY INFORMATION…..6832
INTRODUCTION…..6833
USE OF MACHINE…..6833
DIRECTIONS OF MACHINE…..6833
VISIBILITY FROM OPERATOR'S SEAT…..6834
PRODUCT INFORMATION…..6836
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..6836
EPA REGULATIONS, ENGINE NUMBER PLATE…..6836
SERVICE METER LOCATION…..6837
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..6837
CONTENTS…..6838
SAFETY…..6842
SAFETY…..6843
SAFETY LABELS…..6846
LOCATION OF SAFETY LABELS…..6846
SAFETY LABELS…..6847
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..6853
PRECAUTIONS BEFORE STARTING OPERATION…..6853
PREPARATIONS FOR SAFE OPERATION…..6853
FIRE PREVENTION…..6855
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..6856
DO NOT GET CAUGHT IN WORK EQUIPMENT…..6858
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..6858
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…..6858
UNAUTHORIZED MODIFICATION…..6859
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..6859
PRECAUTIONS RELATED TO CAB GLASS…..6859
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..6859
PRECAUTIONS FOR OPERATION…..6860
PRECAUTIONS FOR JOBSITE…..6860
STARTING ENGINE…..6862
OPERATION…..6864
TRANSPORTATION…..6872
TOWING…..6873
LIFTING OBJECTS WITH BUCKET…..6874
PRECAUTIONS FOR MAINTENANCE…..6875
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..6875
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..6879
OPERATION…..6886
MACHINE VIEW ILLUSTRATIONS…..6887
OVERALL MACHINE VIEW…..6887
CONTROLS AND GAUGES…..6888
DETAILED CONTROLS AND GAUGES…..6890
MONITORING SYSTEM…..6890
SWITCHES…..6955
CONTROL LEVERS AND PEDALS…..6960
SUN ROOF…..6963
WINDSHIELD…..6963
EMERGENCY ESCAPE HAMMER…..6969
DOOR LOCK…..6969
CAP WITH LOCK…..6970
DRINK BOX…..6972
MAGAZINE BOX…..6972
ASHTRAY…..6972
AIR CONDITIONER CONTROLS…..6973
RADIO…..6986
AUXILIARY ELECTRIC POWER…..6991
FUSE…..6992
FUSIBLE LINK…..6993
CONTROLLER…..6993
TOOL BOX…..6994
GREASE PUMP HOLDER…..6994
FIRE EXTINGUISHER…..6994
MACHINE OPERATIONS AND CONTROLS…..6995
BEFORE STARTING ENGINE…..6995
STARTING ENGINE…..7014
AFTER STARTING ENGINE…..7017
STOPPING THE ENGINE…..7028
MACHINE OPERATION…..7029
STEERING THE MACHINE…..7033
SWINGING…..7035
WORK EQUIPMENT CONTROLS AND OPERATIONS…..7036
WORKING MODE…..7038
PROHIBITED OPERATIONS…..7040
GENERAL OPERATION INFORMATION…..7045
TRAVELING ON SLOPES…..7047
ESCAPE FROM MUD…..7049
RECOMMENDED APPLICATIONS…..7050
BUCKET REPLACEMENT AND INVERSION…..7052
PARKING MACHINE…..7056
MACHINE INSPECTION AFTER DAILY WORK…..7057
LOCKING…..7058
TRANSPORTATION…..7059
TRANSPORTATION PROCEDURE…..7059
LOADING AND UNLOADING WITH TRAILER…..7060
LIFTING MACHINE…..7069
TRANSPORTATION POSTURE…..7071
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..7073
COLD WEATHER OPERATION…..7075
COLD WEATHER OPERATION INFORMATION…..7075
AFTER DAILY WORK COMPLETION…..7077
AFTER COLD WEATHER SEASON…..7077
LONG TERM STORAGE…..7078
BEFORE STORAGE…..7078
DURING STORAGE…..7078
AFTER STORAGE…..7079
STARTING MACHINE AFTER LONG-TERM STORAGE…..7079
TROUBLES AND ACTIONS…..7080
RUNNING OUT OF FUEL…..7080
PHENOMENA THAT ARE NOT FAILURES…..7081
TOWING THE MACHINE…..7082
LIGHTWEIGHT TOWING HOLE…..7083
SEVERE JOB CONDITION…..7083
DISCHARGED BATTERY…..7084
OTHER TROUBLE…..7088
MAINTENANCE…..7094
MAINTENANCE INFORMATION…..7095
OUTLINE OF SERVICE…..7097
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..7097
ELECTRIC SYSTEM MAINTENANCE…..7100
WEAR PARTS…..7101
WEAR PARTS LIST…..7101
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..7102
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..7104
TIGHTENING TORQUE SPECIFICATIONS…..7105
TIGHTENING TORQUE LIST…..7105
SAFETY CRITICAL PARTS…..7106
SAFETY CRITICAL PARTS LIST…..7107
MAINTENANCE SCHEDULE…..7108
MAINTENANCE SCHEDULE CHART…..7108
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..7110
MAINTENANCE PROCEDURE…..7111
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…..7111
WHEN REQUIRED…..7112
CHECK BEFORE STARTING…..7139
EVERY 50 HOURS MAINTENANCE…..7140
EVERY 250 HOURS MAINTENANCE…..7141
EVERY 500 HOURS MAINTENANCE…..7146
EVERY 1000 HOURS MAINTENANCE…..7159
EVERY 2000 HOURS MAINTENANCE…..7166
EVERY 4000 HOURS MAINTENANCE…..7173
EVERY 5000 HOURS MAINTENANCE…..7175
EVERY 8000 HOURS MAINTENANCE…..7177
SPECIFICATIONS…..7178
SPECIFICATIONS…..7179
ATTACHMENTS, OPTIONS…..7182
GENERAL PRECAUTIONS FOR SAFETY…..7183
PRECAUTIONS WHEN SELECTING…..7183
READ THE INSTRUCTION MANUAL THOROUGHLY…..7183
PRECAUTIONS WHEN REMOVING OR INSTALLING…..7183
PRECAUTIONS WHEN USING…..7183
BUCKET WITH HOOK…..7184
HOOK CONDITION…..7184
PROHIBITED OPERATIONS…..7184
MACHINE READY FOR ATTACHMENT…..7185
LOCATIONS…..7185
HYDRAULIC CIRCUIT…..7189
ATTACHMENT REMOVAL AND INSTALLATION…..7194
ATTACHMENT OPERATIONS…..7198
LONG TERM STORAGE…..7199
SPECIFICATIONS…..7199
HANDLING THE ELECTRIC PRIMING PUMP…..7200
BLEEDING AIR FROM FUEL CIRCUIT…..7200
ATTACHMENT GUIDE…..7203
ATTACHMENT COMBINATIONS…..7203
TRACK SHOES SELECTION…..7205
RECOMMENDED ATTACHMENT OPERATIONS…..7206
HYDRAULIC BREAKER…..7206
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..7210
BASIC PRECAUTIONS…..7210
INDEX…..7212
TEN00499-02 – Hydraulic Excavator PC400-8, PC400LC-8, PC450-8, PC450LC-8 Operation & Maintenance Manual…..7216
COVER…..7216
FOREWORD…..7217
BEFORE READING THIS MANUAL…..7218
SAFETY INFORMATION…..7219
INTRODUCTION…..7220
USE OF MACHINE…..7220
DIRECTIONS OF MACHINE…..7220
VISIBILITY FROM OPERATOR'S SEAT…..7221
PROTECTIVE STRUCTURE…..7222
PRODUCT INFORMATION…..7223
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..7223
EPA REGULATIONS, ENGINE NUMBER PLATE…..7223
SERVICE METER LOCATION…..7224
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..7224
CONTENTS…..7225
SAFETY…..7229
SAFETY…..7230
SAFETY LABELS…..7233
LOCATION OF SAFETY LABELS…..7233
SAFETY LABELS…..7234
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..7241
PRECAUTIONS BEFORE STARTING OPERATION…..7241
PREPARATIONS FOR SAFE OPERATION…..7241
FIRE PREVENTION…..7243
DO NOT GET CAUGHT IN WORK EQUIPMENT…..7246
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..7246
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…..7247
UNAUTHORIZED MODIFICATION…..7248
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..7248
PRECAUTIONS RELATED TO CAB GLASS…..7248
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..7248
PRECAUTIONS FOR OPERATION…..7249
PRECAUTIONS FOR JOBSITE…..7249
STARTING ENGINE…..7251
OPERATION…..7253
TRANSPORTATION…..7261
TOWING…..7262
LIFTING OBJECTS WITH BUCKET…..7263
PRECAUTIONS FOR MAINTENANCE…..7264
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..7264
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..7268
OPERATION…..7275
MACHINE VIEW ILLUSTRATIONS…..7276
OVERALL MACHINE VIEW…..7276
CONTROLS AND GAUGES…..7277
DETAILED CONTROLS AND GAUGES…..7279
MONITORING SYSTEM…..7279
SWITCHES…..7344
CONTROL LEVERS AND PEDALS…..7349
SUN ROOF…..7352
WINDSHIELD…..7352
EMERGENCY ESCAPE HAMMER…..7358
DOOR LOCK…..7358
CAP WITH LOCK…..7359
DRINK BOX…..7361
MAGAZINE BOX…..7361
ASHTRAY…..7361
AIR CONDITIONER CONTROLS…..7362
RADIO…..7375
AUXILIARY ELECTRIC POWER…..7380
FUSE…..7381
FUSIBLE LINK…..7382
CONTROLLER…..7382
TOOL BOX…..7383
GREASE PUMP HOLDER…..7383
FIRE EXTINGUISHER…..7383
MACHINE OPERATIONS AND CONTROLS…..7384
BEFORE STARTING ENGINE…..7384
STARTING ENGINE…..7403
AFTER STARTING ENGINE…..7406
STOPPING THE ENGINE…..7417
MACHINE OPERATION…..7418
STEERING THE MACHINE…..7422
SWINGING…..7424
WORK EQUIPMENT CONTROLS AND OPERATIONS…..7425
WORKING MODE…..7427
PROHIBITED OPERATIONS…..7429
GENERAL OPERATION INFORMATION…..7434
TRAVELING ON SLOPES…..7436
ESCAPE FROM MUD…..7438
RECOMMENDED APPLICATIONS…..7439
PARKING MACHINE…..7445
MACHINE INSPECTION AFTER DAILY WORK…..7446
LOCKING…..7447
TRANSPORTATION…..7448
TRANSPORTATION PROCEDURE…..7448
LOADING AND UNLOADING WITH TRAILER…..7449
LIFTING MACHINE…..7458
TRANSPORTATION POSTURE…..7460
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…..7462
COLD WEATHER OPERATION…..7464
COLD WEATHER OPERATION INFORMATION…..7464
AFTER DAILY WORK COMPLETION…..7466
AFTER COLD WEATHER SEASON…..7466
LONG TERM STORAGE…..7467
BEFORE STORAGE…..7467
DURING STORAGE…..7467
AFTER STORAGE…..7468
STARTING MACHINE AFTER LONG-TERM STORAGE…..7468
TROUBLES AND ACTIONS…..7469
RUNNING OUT OF FUEL…..7469
PHENOMENA THAT ARE NOT FAILURES…..7470
TOWING THE MACHINE…..7471
LIGHTWEIGHT TOWING HOLE…..7472
SEVERE JOB CONDITION…..7472
DISCHARGED BATTERY…..7473
OTHER TROUBLE…..7477
MAINTENANCE…..7483
MAINTENANCE INFORMATION…..7484
OUTLINE OF SERVICE…..7486
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..7486
ELECTRIC SYSTEM MAINTENANCE…..7489
WEAR PARTS…..7490
WEAR PARTS LIST…..7490
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..7491
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..7493
TIGHTENING TORQUE SPECIFICATIONS…..7494
TIGHTENING TORQUE LIST…..7494
SAFETY CRITICAL PARTS…..7495
SAFETY CRITICAL PARTS LIST…..7496
MAINTENANCE SCHEDULE…..7497
MAINTENANCE SCHEDULE CHART…..7497
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..7499
MAINTENANCE PROCEDURE…..7500
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…..7500
WHEN REQUIRED…..7501
CHECK BEFORE STARTING…..7528
EVERY 50 HOURS MAINTENANCE…..7529
EVERY 250 HOURS MAINTENANCE…..7530
EVERY 500 HOURS MAINTENANCE…..7535
EVERY 1000 HOURS MAINTENANCE…..7548
EVERY 2000 HOURS MAINTENANCE…..7555
EVERY 4000 HOURS MAINTENANCE…..7562
EVERY 5000 HOURS MAINTENANCE…..7564
EVERY 8000 HOURS MAINTENANCE…..7566
SPECIFICATIONS…..7567
SPECIFICATIONS…..7568
ATTACHMENTS AND OPTIONS…..7571
GENERAL PRECAUTIONS FOR SAFETY…..7572
PRECAUTIONS WHEN SELECTING…..7572
READ THE INSTRUCTION MANUAL THOROUGHLY…..7572
PRECAUTIONS WHEN REMOVING OR INSTALLING…..7572
PRECAUTIONS WHEN USING…..7572
BUCKET WITH HOOK…..7573
HOOK CONDITION…..7573
PROHIBITED OPERATIONS…..7573
MACHINE READY FOR ATTACHMENT…..7574
LOCATIONS…..7574
HYDRAULIC CIRCUIT…..7578
ATTACHMENT REMOVAL AND INSTALLATION…..7583
ATTACHMENT OPERATIONS…..7587
LONG TERM STORAGE…..7588
SPECIFICATIONS…..7588
HANDLING THE ELECTRIC PRIMING PUMP…..7589
BLEEDING AIR FROM FUEL CIRCUIT…..7589
ATTACHMENT GUIDE…..7592
ATTACHMENT COMBINATIONS…..7592
TRACK SHOES SELECTION…..7594
RECOMMENDED ATTACHMENT OPERATIONS…..7595
HYDRAULIC BREAKER…..7595
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..7599
BASIC PRECAUTIONS…..7599
INDEX…..7601
Komatsu Hydraulic Excavators PC400, PC400LC, PC450, PC450LC Repair Service Manuals
