Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC400LC-6LK, PC400HD-6LK, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC400LC-6LK, PC400HD-6LK avance 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.
CEAM002901 – Hydraulic Excavator PC400LC-6LK, PC400HD-6LK avance Operation & Maintenance Manual.pdf
CEBM002502 – Hydraulic Excavator PC400LC-6LK, PC400HD-6LK avance Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,123 pages
File Format: PDF
Language: English
CEAM002901 – Hydraulic Excavator PC400LC-6LK, PC400HD-6LK avance Operation & Maintenance Manual….2
COVER….2
INTRODUCTION….8
FOREWORD….9
SAFETY INFORMATION….9
INTRODUCTION….10
INTENDED USE….10
FEATURES….10
BREAKING IN THE MACHINE….10
LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR….11
P.I.N. PLATE LOCATION….11
ENGINE SERIAL NO. PLATE LOCATION….11
TABLE TO ENTER NUMBERS AND DISTRIBUTOR….11
TABLE OF CONTENTS….12
SAFETY….20
WARNING LABELS….21
GENERAL PRECAUTIONS….26
SAFETY RULES….26
SAFETY FEATURES….26
UNAUTHORIZED MODIFICATION….26
INSIDE OPERATOR’S COMPARTMENT….26
CLOTHING AND PERSONAL PROTECTIVE ITEMS….27
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT….27
MOUNTING AND DISMOUNTING….27
INJURY FROM WORK EQUIPMENT….28
FIRE PREVENTION FOR FUEL AND OIL….28
PRECAUTIONS AT HIGH TEMPERATURES….28
ASBESTOS DUST HAZARD PREVENTION….29
FIRE EXTINGUISHER AND FIRST AID KIT….29
CAB GLASS….29
WINDOW WASHER FLUID….29
ESCAPE FROM FIRE….29
PROTECTION AGAINST FALLING OR FLYING OBJECTS….30
MACHINES WITH ACCUMULATOR….30
PRECAUTIONS FOR ATTACHMENTS….30
INDOOR VENTILATION….31
EMERGENCY EXIT FROM OPERATORS CAB….31
PRECAUTIONS DURING OPERATION….32
BEFORE STARTING ENGINE….32
SAFETY AT WORK SITE….32
FIRE PREVENTION….32
VENTILATION FOR ENCLOSED AREAS….32
IN OPERATOR’S CAB….33
PRECAUTIONS FOR MIRROR AND LIGHTS….33
WHEN STARTING ENGINE….33
OPERATING MACHINE….34
WHEN STARTING ENGINE….34
CHECK DIRECTION BEFORE STARTING MACHINE….34
CHECK THAT NO ONE IS IN AREA BEFORE SWINGING OR TRAVELING IN REVERSE….34
NEVER LET ANYONE RIDE ON ATTACHMENT….34
PRECAUTIONS WHEN TRAVELING….35
OPERATE CAREFULLY ON SNOW….35
TRAVELING ON SLOPES….36
PROHIBITED OPERATIONS….36
PRECAUTIONS FOR OPERATION….37
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES….37
WORKING ON LOOSE GROUND….38
OPERATING ON SLOPES….38
PARKING THE MACHINE….38
PRECAUTIONS IN COLD WEATHER….39
TRANSPORTATION….40
LOADING AND UNLOADING….40
PRECAUTIONS WHEN LIFTING….40
SHIPPING….41
BATTERY….42
BATTERY HAZARD PREVENTION….42
STARTING WITH BOOSTER CABLES….42
CHARGING BATTERY….43
TOWING….44
PRECAUTIONS WHEN TOWING….44
BUCKET WITH HOOK….45
PROHIBITED OPERATIONS….45
PRECAUTIONS WHEN INSTALLING AND OPERATING BUCKET WITH HOOK….45
BEFORE CARRYING OUT MAINTENANCE….46
CONTACT WHEN THERE IS FAILURE….46
WARNING TAG….46
CLEAN BEFORE INSPECTION OR MAINTENANCE….46
NEAT CLEAN WORK PLACE….46
FOLLOW LEADER IN OPERATIONS WITH OTHER WORKERS….46
RADIATOR COOLANT LEVEL….47
DO NOT DISASSEMBLE RECOIL SPRING….47
PROPER TOOLS….47
STOP ENGINE PRIOR TO INSPECTION AND MAINTENANCE….47
SUPPORT FOR WORK EQUIPMENT….48
PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS….48
USE OF LIGHTING….48
FIRE PREVENTION….48
RULES TO FOLLOW WHEN ADDING FUEL OR OIL….49
PRECAUTIONS FOR MAINTENANCE….46
DURING MAINTENANCE….50
PERSONNEL….50
REMOVAL, INSTALLATION AND STORAGE OF ATTACHMENTS….50
WORK UNDER THE MACHINE….50
NOISE….50
WHEN WORKING ON MACHINE….50
LOCK INSPECTION COVERS….50
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….51
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE….51
FLYING PIECES WITH HAMMER WORK….51
KEEP THE MACHINE CLEAN….51
WELDING REPAIRS….52
REMOVE BATTERY TERMINALS….52
ACTION WHEN ABNORMALITY IS FOUND DURING INSPECTION….52
RULES TO FOLLOW WHEN ADDING FUEL….52
WHEN ADJUSTING TRACK TENSION….53
HANDLING HIGH PRESSURE HOSES….53
WITH HIGH PRESSURE OIL….53
WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE/PRESSURE….54
WASTE MATERIALS….54
CHECKS AFTER INSPECTION AND MAINTENANCE….54
MAINTENANCE FOR AIR CONDITIONER….54
OPERATION….55
GENERAL….56
GENERAL VIEW OF MACHINE….56
GENERAL VIEW OF OPERATORS COMPARTMENT….57
GENERAL VIEW OF MONITOR PANEL….58
EXPLANATION OF COMPONENTS….59
MACHINE MONITOR….59
MONITOR LIGHT GROUP….61
METER DISPLAY PORTION….63
SWITCHES….66
SWITCHES….69
CONTROL LEVERS AND PEDALS….74
ATTACHMENT CONTROLS….77
OPERATOR’S SEAT….79
SEAT ADJUSTMENT….79
SEAT BELT….81
FASTENING AND REMOVING….81
ADJUST THE BELT LENGTH….81
MONITOR PANEL….82
ADJUSTMENT ANGLE….82
ROOF VENT….82
WHEN OPENING….82
WHEN CLOSING….82
FRONT WINDOW….83
WHEN OPENING….83
WHEN CLOSING….84
FRONT BOTTOM WINDOW….85
DOOR LOCK….85
CAP, COVER WITH LOCK….86
METHOD OF OPENING AND CLOSING LOCK CAP….86
METHOD OF OPENING AND CLOSING COVER LOCK….86
OPERATOR EASE….87
HOT AND COOL BOX….87
STORAGE BOX….87
ASHTRAY….87
AIR CONDITIONER….88
GENERAL LOCATIONS ON CONTROL PANEL….88
PRECAUTIONS WHEN USING AIR CONDITIONER….90
CHECK, MAINTAIN AIR CONDITIONER….90
CAB HEATER….91
GENERAL LOCATION….91
HEATER FAN SWITCH….91
VENT SELECTOR SWITCH….92
DEFROSTER SELECTOR LEVER….92
PREPARATION FOR HEATER….93
AM/FM RADIO….94
EXPLANATION OF COMPONENTS….94
METHOD OF OPERATION….96
PRECAUTIONS WHEN USING….98
SPECIFICATIONS….98
ELECTRIC POWER TAKE OUT ADAPTER….98
FUSE….99
FUSIBLE LINK….100
CONTROLLERS….100
TOOL BOX….100
GREASE GUN HOLDER….100
HANDLING ACCUMULATOR….101
RELEASING PRESSURE ON MACHINE EQUIPPED WITH ACCUMULATOR….101
OPERATION….102
CHECK BEFORE STARTING ENGINE….102
WALK AROUND CHECK….102
CHECK BEFORE STARTING….104
ADJUSTMENT OF MIRRORS….107
ADJUST OPERATOR’S SEAT….107
ADJUST SEAT BELT….107
ADJUST ARM RESTS….107
ADJUST MONITOR PANEL….107
OPERATIONS AND CHECKS BEFORE STARTING ENGINE….108
STARTING ENGINE….110
NORMAL STARTING….110
STARTING IN COLD WEATHER….111
OPERATIONS AND CHECKS AFTER STARTING ENGINE….113
WHEN NORMAL….113
IN COLD AREAS (AUTOMATIC WARM UP OPERATION)….116
MOVING MACHINE….119
MOVING MACHINE FORWARD….119
MOVING MACHINE REARWARD….120
STEERING MACHINE….122
STEERING (CHANGING DIRECTION)….122
STOPPING MACHINE….124
SWINGING….125
OPERATION OF WORK EQUIPMENT….126
HANDLING ACTIVE MODE….127
HANDLING WORKING MODE….128
WORKING MODE….128
POWER MAX., SWIFT SLOW DOWN….128
PROHIBITIONS FOR OPERATION….130
PROHIBITED OPERATIONS USING SWING FORCE….130
PROHIBITED OPERATIONS USING TRAVEL FORCE….130
PRECAUTIONS WHEN OPERATING CYLINDERS TO END OF STROKE….130
PROHIBITED OPERATIONS USING DROPPING FORCE OF BUCKET….131
PROHIBITED OPERATIONS USING DROPPING FORCE OF MACHINE….131
DIGGING ROCKY GROUND….131
SUDDEN LEVER SHIFTING DURING HI SPEED TRAVEL PROHIBITED….131
PRECAUTIONS FOR OPERATION….132
PRECAUTIONS WHEN TRAVELING….132
PRECAUTIONS AT HI SPEED TRAVEL….132
PERMISSIBLE WATER DEPTH….132
PRECAUTIONS WHEN TRAVELING ON HILLS….133
BRAKING WHEN TRAVELING DOWNHILL….134
IF SHOES SLIP….134
IF ENGINE STOPS….134
PRECAUTIONS ON SLOPES….134
HOW TO ESCAPE FROM MUD….135
WHEN ONE SIDE IS STUCK….135
WHEN BOTH SIDES ARE STUCK….135
WORK POSSIBLE USING EXCAVATOR….136
BACKHOE WORK….136
SHOVEL WORK….136
DITCHING WORK….136
LOADING WORK….137
BUCKET REPLACEMENT OR INVERSION….138
REPLACEMENT….138
INVERSION….139
PARKING MACHINE….140
CHECK AFTER FINISHING WORK….142
STOPPING ENGINE….142
CHECK AFTER STOPPING ENGINE….142
LOCKING….143
TRANSPORTATION….144
TRANSPORTATION PROCEDURE….144
LOADING, UNLOADING WORK ON TRAILERS….144
LOADING….145
UNLOADING….146
SECURING MACHINE….148
REMOVAL, INSTALLATION OF MIRRORS….149
METHOD OF LIFTING MACHINE….149
TRACK FRAME GAUGE….151
REDUCING TRACK GAUGE….151
INCREASING TRACK GAUGE….151
COLD WEATHER OPERATION….152
PRECAUTIONS FOR LOW TEMPERATURE….152
FUEL AND LUBRICANTS….152
COOLANT….152
BATTERY….153
PRECAUTIONS AFTER COMPLETION OF WORK….154
AFTER COLD WEATHER….154
LONG TERM STORAGE….155
BEFORE STORAGE….155
DURING STORAGE….155
AFTER STORAGE….155
MACHINE START AFTER LONG TERM STORAGE….156
TROUBLESHOOTING….157
PHENOMENA THAT ARE NOT FAILURES….157
METHOD OF TOWING DISABLED MACHINE….157
USING MACHINE FOR LIGHT WEIGHT TOWING….157
PRECAUTIONS ON PARTICULAR JOB SITES….157
DISCHARGED BATTERY….158
REMOVING AND INSTALLING BATTERY….158
PRECAUTIONS FOR CHARGING BATTERY….158
STARTING ENGINE WITH BOOSTER CABLE….159
OTHER TROUBLE….161
ELECTRICAL SYSTEM….161
CHASSIS….162
ENGINE….163
ELECTRONIC CONTROL SYSTEM….164
MAINTENANCE….165
GUIDES TO MAINTENANCE….166
OUTLINES OF SERVICE….168
OUTLINE OF OIL, FUEL, COOLANT….168
OIL….168
FUEL….168
COOLANT….169
GREASE….169
STORING OIL AND FUEL….169
FILTERS….169
RELATING TO ELECTRICAL SYSTEM….169
OUTLINE OF HYDRAULIC SYSTEM….170
WEAR PARTS LIST….171
USE OF FUEL, COOLANT AND LUBRICANTS….172
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS….172
ABBREVIATIONS….172
ENGINE OIL SPECIFICATIONS….173
NORMAL OPERATION….173
ARCTIC OPERATION….173
DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYD…..174
FINAL DRIVE OIL SPECIFICATIONS….174
FUEL SYSTEM….174
COOLING SYSTEM….175
GENERAL….175
WATER….175
ANTIFREEZE….175
INHIBITORS/CONDITIONERS….176
SUPPLEMENTAL COOLANT ADDITIVES….176
STANDARD TIGHTENING TORQUES….180
INTRODUCTION OF NECESSARY TOOLS….180
BOLT IDENTIFICATION CHART….181
PERIODIC REPLACEMENT OF CRITICAL PARTS….182
MAINTENANCE SCHEDULE CHART….183
MAINTENANCE INTERVAL WHEN USING BREAKER….185
SERVICE PROCEDURE….186
INITIAL 250 HOURS SERVICE….186
FUEL FILTER CARTRIDGE….186
REPLACE ENGINE BYPASS FILTER CARTRIDGE….187
ENGINE VALVE CLEARANCE….188
WHEN REQUIRED….189
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….189
DRAIN, FLUSH AND REFILL COOLING SYSTEM….191
CHECK AND TIGHTEN TRACK SHOE BOLTS….193
CHECK AND ADJUST TRACK TENSION….193
CHECK ELECTRICAL INTAKE AIR HEATER….195
BUCKET TEETH REPLACEMENT….196
ADJUST BUCKET CLEARANCE….198
CHECK WINDOW WASHER FLUID, ADD FLUID….199
CHECK, MAINTAIN AIR CONDITIONER….199
REPLACE ADDITIONAL BREAKER FILTER ELEMENT….200
CLEAN IN LINE FILTERS….202
CHECK BEFORE STARTING….203
CHECK COOLANT LEVEL, ADD COOLANT….203
CHECK ENGINE OIL LEVEL, ADD OIL….203
CHECK FUEL LEVEL, ADD FUEL….204
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….204
CHECK AIR CLEANER FOR CLOGGING….205
CHECK ELECTRIC WIRING….205
CHECK FUNCTION OF HORN….205
CHECK FOR WATER/SEDIMENT IN FUEL FILTER, DRAIN….206
EVERY 50 HOURS SERVICE….207
GREASE LUBRICATION….207
EVERY 100 HOURS SERVICE….209
PREVIOUS MAINTENANCE….209
LUBRICATION….209
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL….210
DRAIN WATER AND SEDIMENT FROM FUEL TANK….210
EVERY 250 HOURS SERVICE….211
PREVIOUS MAINTENANCE….211
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….211
CHECK LEVEL OF BATTERY ELECTROLYTE….211
CHANGE ENGINE OIL, REPLACE FILTER CARTRIDGE….212
LUBRICATE SWING CIRCLE (3 POINTS)….214
CHECK FAN BELT TENSION, ADJUST….214
CHECK, ADJUST TENSION OF A/C COMPRESSOR BELT….215
EVERY 500 HOURS SERVICE….216
PREVIOUS MAINTENANCE….216
FUEL FILTER CARTRIDGE….216
CHECK SWING PINION GREASE LEVEL, ADD GREASE….217
CLEAN AND INSPECT RADIATOR, OIL COOLER AND CONDENSER FINS….217
CLEAN FILTERS OF AIR CONDITIONER….218
REPLACE HYDRAULIC TANK BREATHER ELEMENT….218
REPLACE HYDRAULIC FILTER ELEMENT….219
EVERY 1000 HOURS SERVICE….220
CHANGE OIL IN SWING MACHINERY CASE….220
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL….220
REPLACE CORROSION RESISTOR CARTRIDGE….221
REPLACE HYDRAULIC TANK RELIEF VALVE ELEMENT….222
CHECK TIGHTENING PARTS OF TURBOCHARGER….222
CHECK PLAY OF TURBOCHARGER ROTOR….222
EVERY 2000 HOURS SERVICE….223
CHANGE OIL IN FINAL DRIVE CASE….223
CLEAN HYDRAULIC TANK STRAINER….223
CLEAN ENGINE BREATHER….224
CLEAN, CHECK TURBOCHARGER….224
CHECK ALTERNATOR, STARTING MOTOR….224
CHECK ENGINE VALVE CLEARANCE, ADJUST….224
CHECK VIBRATION DAMPER….224
CHECK, ADJUST FUEL INJECTION NOZZLES….224
EVERY 4000 HOURS SERVICE….225
CHECK WATER PUMP….225
REPLACE FUEL INJECTION NOZZLE TIPS….225
EVERY 5000 HOURS SERVICE….226
CHANGE OIL IN HYDRAULIC TANK….226
SPECIFICATIONS….230
SPECIFICATIONS AND DIMENSIONS….231
SPECIFICATIONS….231
DIMENSIONS….233
PC400LC-6LK….233
PC400HD-6LK….245
OPTIONS, ATTACHMENTS….254
GENERAL PRECAUTIONS….255
PRECAUTIONS RELATED TO SAFETY….255
PRECAUTIONS WHEN INSTALLING ATTACHMENTS….256
BUCKET WITH HOOK….257
CHECKING FOR DAMAGE….257
PROHIBITED OPERATIONS….257
PRECAUTIONS DURING OPERATIONS….257
MACHINES READY FOR ATTACHMENT….258
GENERAL LOCATIONS….258
HYDRAULIC CIRCUIT….261
SWITCHING TO FILTER CIRCUIT….261
CONNECTING HYDRAULIC CIRCUIT….261
PATH OF OIL FLOW….262
ATTACHMENT REMOVAL AND INSTALLATION….263
PROCEDURE FOR REMOVAL….263
PROCEDURE FOR INSTALLATION….263
OPERATION….264
WHEN USING BREAKER….264
WHEN USING GENERAL ATTACHMENT….264
LONG TERM STORAGE….265
SPECIFICATIONS….265
INTRODUCTION OF ATTACHMENTS….266
ATTACHMENT INSTALLATION COMBINATION TABLE….266
BUCKET SELECTION….267
STANDARD DUTY PLATE BUCKET….267
HEAVY DUTY PLATE BUCKET….267
HEAVY DUTY CAST BUCKET….267
DITCH CLEANING BUCKET….267
SELECTION OF TRACK SHOES….268
EXTENDING MACHINE SERVICE LIFE….269
HYDRAULIC BREAKER….269
MAIN FIELDS OF APPLICATION….269
MISTAKEN METHODS OF USE….270
GREASING POSITION FOR HYDRAULIC BREAKER….272
POWER RIPPER….273
MAIN FIELDS OF APPLICATION….273
MISTAKEN METHODS OF USE….273
GRAB FORK….275
MAIN FIELDS OF APPLICATION….275
MISTAKEN METHODS OF USE….275
GRAPPLE BUCKET….276
MAIN FIELDS OF APPLICATION….276
MISTAKEN METHODS OF USE….276
SCRAP GRAPPLE….278
MAIN FIELDS OF APPLICATION….278
MISTAKEN METHODS OF USE….278
CRUSHER AND CUTTER….280
MAIN FIELDS OF APPLICATION….280
MISTAKEN METHODS OF USE….280
HYDRAULIC PILE DRIVER….281
MAIN FIELDS OF APPLICATION….281
MISTAKEN METHODS OF USE….281
MULTIPURPOSE CRANE….283
MAIN FIELDS OF APPLICATION….283
MISTAKEN METHODS OF USE….283
CEBM002502 – Hydraulic Excavator PC400LC-6LK, PC400HD-6LK avance Shop Manual….288
COVER….288
CONTENTS….289
FOREWORD….300
SAFETY….300
SAFETY NOTICE….300
IMPORTANT SAFETY NOTICE….300
GENERAL PRECAUTIONS….300
PREPARATIONS FOR WORK….300
PRECAUTIONS DURING WORK….300
GENERAL….302
HOW TO READ THE SHOP MANUAL….303
VOLUMES….303
DISTRIBUTION AND UPDATING….303
FILING METHOD….303
REVISED EDITION MARK….303
REVISIONS….303
SYMBOLS….303
HOISTING INSTRUCTIONS….304
HOISTING….304
WIRE ROPES….304
COATING MATERIALS….305
STANDARD TIGHTENING TORQUE….307
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS….307
TIGHTENING TORQUE OF HOSE NUTS….308
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS….308
TIGHTENING TORQUE FOR FLARED NUTS….308
ELECTRIC WIRE CODE….309
CLASSIFICATION BY THICKNESS….309
CLASSIFICATION BY COLOR AND CODE….309
CONVERSION TABLES….310
METHOD OF USING THE CONVERSION TABLE….310
01 GENERAL….316
SPECIFICATION DRAWINGS….317
MACHINE….317
WORK EQUIPMENT….319
SPECIFICATIONS….321
WEIGHT TABLE….323
FUEL COOLANT AND LUBRICANTS….325
10 STRUCTURE AND FUNCTION….326
PARTS RELATED TO ENGINE….330
ENGINE MOUNT TORQUES….332
RADIATOR, OIL COOLER….334
RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (1/4)….335
RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (2/4)….336
RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (3/4)….337
RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (4/4)….339
POWER TRAIN….340
FINAL DRIVE….342
FINAL DRIVE SPECIFICATIONS AND TORQUES….343
SWING CIRCLE….345
SWING CIRCLE SPECIFICATIONS AND TORQUES….346
SWING MACHINERY….348
SWING MACHINERY SPECIFICATIONS AND TORQUES….349
TRACK FRAME, RECOIL SPRING….351
PC400LC-6LK….351
TRACK FRAME, RECOIL SPRING TORQUES PC400LC-6LK….352
PC400LC-6LK – VARIABLE GAUGE….353
TRACK FRAME, RECOIL SPRING TORQUES PC400LC-6LK – VARIABLE GAUGE….354
PC400HD-6LK….355
TRACK FRAME, RECOIL SPRING TORQUES PC400HD-6LK….356
TRACK SHOE….358
TRACK SHOE SPECIFICATIONS….361
CARRIER ROLLER….362
IDLER….363
TRACK ROLLER….365
HYDRAULIC PIPING DRAWING….367
HYDRAULIC CIRCUIT DIAGRAM….369
HYDRAULIC TANK, HYDRAULIC FILTER….370
HYDRAULIC PUMP….371
HPV 160 + 160….371
HYDRAULIC PUMP TORQUES….374
TVC, LS VALVE….378
LS VALVE – OPERATION….381
TVC VALVE – OPERATION….385
HYDRAUIC CYLINDER….393
BOOM, BUCKET CYLINDER – THREADED PISTON….393
BOOM, BUCKET CYLINDER – CLAMPED PISTON….393
ARM CYLINDER – THREADED PISTON….393
ARM CYLINDER – CLAMPED PISTON….393
CONTROL VALVE….395
10 SPOOL VALVE – STD. AND 3 SERVICE VALVES….395
9 SPOOL VALVE – STD AND 2 SERVICE VALVES….401
8 SPOOL VALVE – STD AND 1 SERVICE VALVES….402
7 SPOOL VALVE – STD….403
CONTROL VALVE SPECIFICATIONS AND TORQUES….405
10 SPOOL VALVE….405
SELF REDUCING PRESSURE VALVE….411
SELF REDUCING PRESSURE VALVE SPECIFICATIONS….411
SUCTION SAFETY VALVE….417
FOR SERVICE….417
SUCTION SAFETY VALVE SPECIFICATIONS AND TORQUES….418
CLSS….419
OUTLINE OF CLSS….419
BASIC PRINCIPLE….420
CONTROL OF PUMP SWASH PLATE ANGLE….420
PRESSURE COMPENSATION….421
OPERATION FOR EACH FUNCTION OF CLSS….422
SYSTEM DIAGRAM….423
WHEN UNLOAD VALVE IS ACTUATED….424
OPERATION OF RELIEF VALVE….425
CUT-OFF CONTROL ACTUATED….425
CUT-OFF CANCELED….425
INTRODUCTION OF LS PRESSURE….426
LS BYPASS VALVE….427
PRESSURE COMPENSATION VALVE….428
SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE….431
VARIABLE TYPE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE)….433
VARIABLE PRESSURE COMPENSATION VALVE SPECIFICATIONS AND TORQUES….434
BOOM REGENERATION CIRCUIT….435
ARM REGENERATION CIRCUIT….437
MERGE FLOW DIVIDER VALVE….439
LS SELECT VALVE….441
2-STAGE SAFETY VALVE (INSTALLED TO BOOM CYLINDER HEAD)….442
OPERATION OF CLSS SYSTEM AS A WHOLE….443
WHEN ALL WORK EQUIPMENT IS AT NEUTRAL….443
WHEN PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY….444
WHEN PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY….444
WHEN PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY….444
WHEN PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY….445
WHEN PUMP DIVIDED, TRAVEL OPERATED INDEPENDENTLY….445
WHEN PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY….445
WHEN PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY….446
WHEN PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY….446
WHEN PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY….446
SWING MOTOR….447
SWING MOTOR SPECIFICATIONS AND TORQUES….449
SUCTION-SAFETY VALVE….450
SWING BRAKE….451
CENTER SWIVAL JOINT….452
CENTER SWIVEL JOINT SPECIFICATIONS….453
TRAVEL MOTOR….455
MOTOR OPERATION….459
AT LOW SPEED….459
AT HIGH SPEED….460
PARKING BRAKE OPERATION….461
BRAKE VALVE OPERATION….461
SAFETY VALVE….463
VALVE CONTROL….466
WORK EQUIPMENT PPC VALVE….467
OPERATION….469
AT NEUTRAL….469
DURING FINE CONTROL (NEUTRAL Æ FINE CONTROL)….469
DURING FINE CONTROL (WHEN LEVER IS RETURNED)….470
AT FULL STROKE….470
WORK EQUIPMENT AND SWING PPC VALVE SPECIFICATIONS AND TORQUES….471
TRAVEL PPC VALVE….472
OPERATION….474
AT NEUTRAL….474
FINE CONTROL (NEUTRAL –> FINE CONTROL)….474
FINE CONTROL (CONTROL LEVER RETURNED)….475
AT FULL STROKE….475
TRAVEL PPC VALVE SPECIFICATIONS AND TORQUE….477
SERVICE PPC VALVE….479
SERVICE PPC VALVE SPECIFICATIONS AND TORQUES….481
PPC SAFETY LOCK VALVE….482
PPC ACCUMULATOR….483
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE….484
PPC SHUTTLE VALVE….485
TRAVEL JUNCTION VALVE….488
STRAIGHT-TRAVEL SYSTEM….489
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE SPECIFICATIONS AND TORQUES….491
LS-EPC VALVE….492
LS-EPC VALVE SPECIFICATIONS AND TORQUES….495
SOLENOID VALVE….496
SOLENOID VALVE TORQUES….498
BOOM HOLDING VALVE….499
BOOM HOLDING VALVE SPECIFICATIONS AND TORQUES….502
WORK EQUIPMENT….504
WORK EQUIPMENT SPECIFICATIONS….505
DIMENSIONS OF WORK EQUIPMENT….507
ARM….507
BUCKET….509
AIR CONDITIONER….512
A/C PIPING….512
A/C ELECTRICAL WIRING DIAGRAM….513
ENGINE CONTROL….517
OPERATION….518
STARTING ENGINE….518
ENGINE SPEED CONTROL….518
STOPPING ENGINE….518
COMPONENTS….519
FUEL CONTROL DIAL….519
GOVERNOR MOTOR….521
GOVERNOR, PUMP CONTROLLER….523
INPUT OUTPUT SIGNALS….524
ELECTRONIC CONTROL SYSTEM….526
CONTROL FUNCTION….526
TOTAL SYSTEM DIAGRAM….526
PUMP AND ENGINE CONTROL SYSTEM….527
PUMP AND VALVE CONTROL FUNCTION….530
CUT-OFF FUNCTION….531
CUT-OFF CANCEL FUNCTION….531
FINE CONTROL MODE FUNCTION….532
POWER MAX. FUNCTION, SWIFT SLOW-DOWN FUNCTION….533
AUTO DECELERATION SYSTEM….534
AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION….536
SWING CONTROL SYSTEM….539
TRAVEL CONTROL SYSTEM….541
ACTIVE MODE FUNCTION….543
INCREASE IN ENGINE SPEED….544
COMPONENTS OF SYSTEM….545
ENGINE SPEED SENSOR….545
PPC HYDRAULIC SWITCH….545
PUMP PRESSURE SENSOR….546
TVC PROLIX RESISTOR….547
MACHINE MONITOR SYSTEM….549
MONITOR PANEL….550
MONITOR DISPLAY….551
CONTENT OF DISPLAY….552
OIL MAINTENANCE FUNCTION….553
MODE SELECTION SWITCHES….555
SWITCH ACTUATION TABLE….555
SENSORS….556
20 TESTING, ADJUSTING AND TROUBLESHOOTING….560
STANDARD VALUE TABLES….562
ENGINE RELATED PARTS….562
CHASSIS RELATED PARTS….563
ELECTRICAL PARTS….568
TESTING AND ADJUSTING….574
SERVICE TOOLS….576
ENGINE….577
BLOW BY PRESSURE….577
BOOST PRESSURE….577
COMPRESSION PRESSURE….577
ENGINE OIL PRESSURE….577
ENGINE SPEED SENSOR….577
ENGINE SPEED (rpm)….577
EXHAUST COLOR….577
FUEL INJECTION TIMING….577
VALVE CLEARANCE….577
GOVERNOR MOTOR LEVER S TROKE….578
FAN BELT TENSION….579
A/C COMPRESSOR BELT….579
WORK EQUIPMENT, SWING, TRAVEL CIRCUIT….580
TVC VALVE OUTPUT PRESSURE….583
LS VALVE OUTPUT PRESSURE….585
LS DIFFERENTIAL PRESSURE….585
CONTROL CIRCUIT OIL PRESSURE….588
SOLENOID VALVE OUTPUT PRESSURE….589
PPC VALVE OUTPUT PRESSURE….592
PPC SHUTTLE VALVE….592
WORK EQUIPMENT, SWING PPC VALVE….594
WORK EQUIPMENT….596
HYDRAULIC DRIFT – LOCATIONS CAUSING….596
CYLINDER PACKING….596
BOOM LOCK VALVE….597
PPC VALVE….597
OIL LEAKAGE….598
WORK EQUIPMENT CYLINDER….598
SWING MOTOR….599
TRAVEL MOTOR….599
RELEASING REMAINING PRESSURE….600
TESTING CLEARANCE OF SWING CIRCLE BEARING….601
SPROCKET WEAR….602
TRACK SHOE TENSION….603
BLEEDING AIR….604
BLEEDING AIR FROM HYDRAULIC CYLINDERS….605
BLEEDING AIR FROM SWING MOTOR….605
BLEEDING AIR FROM TRAVEL MOTOR….605
TROUBLESHOOTING GENERAL….606
POINTS TO REMEMBER WHEN TROUBLESHOOTING….608
SEQUENCE OF EVENTS IN TROUBLESHOOTING….610
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….611
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT….611
HANDLING WIRING HARNESSES AND CONNECTORS….611
REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES….613
HANDLING CONTROL BOX….616
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS….617
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT….617
CHECKS BEFORE TROUBLESHOOTING….619
CONNECTOR TYPES AND MOUNTING LOCATIONS….620
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….626
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM….636
EXPLANATION OF MACHINE CONTROL FUNCTIONS….636
DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL….637
DISPLAY ON MACHINE MONITOR….637
RECORDING OF SERVICE CODES AND USER CODE DISPLAY FUNCTION….637
METHOD OF DISPLAYING TROUBLE DATA….638
MACHINE DATA MONITORING FUNCTION….639
METHOD OF DISPLAYING MONITORING CODE….639
TABLE OF MACHINE MONITORING CODES….640
BIT PATTERN CHART….641
GOVERNOR MOTOR ADJUSTMENT MODE….643
TIME ADJUSTMENT MODE….643
WORKING MODE DEFAULT SETTING MODE….644
METHOD OF USING JUDGEMENT TABLE….645
METHOD OF USING TROUBLESHOOTING CHARTS….647
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE….647
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE….651
PROCEDURE FOR CHECKING MONITOR PANEL OUTPUT SIGNAL….653
CHECKING INPUT SIGNAL OF GOVERNOR, PUMP CONTROLLER….654
PUMP CONTROL SYSTEM….654
GOVERNOR CONTROL SYSTEM….657
SERVICE CODE TABLE….658
TROUBLESHOOTING ELECTRICAL SYSTEM ON GOVERNOR PUMP CONTROLLER (C-MODE)….660
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM….662
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF….662
USER CODE MEMORY RETENTION FUNCTION….662
INFORMATION CONTAINED IN TESTING PROCEDURES….663
(C-1)….665
CONTROLLER POWER SOURCE (LED) IS OFF….665
(C-2)….667
SHORT IN FRONT PUMP (TVC) SOLENOID SYSTEM….667
(C-3)….669
OPEN IN FRONT PUMP (TVC) SOLENOID SYSTEM….669
(C-4)….671
SHORT IN REAR PUMP (TVC) SOLENOID SYSTEM….671
(C-5)….673
OPEN IN REAR PUMP (TVC) SOLENOID SYSTEM….673
(C-6)….675
SHORT IN (LS) SELECT SOLENOID SYSTEM….675
(C-7)….676
OPEN IN (LS) SELECT SOLENOID SYSTEM….676
(C-8)….677
SHORT IN SWING BRAKE SOLENOID SYSTEM….677
(C-9)….679
OPEN IN SWING BRAKE SOLENOID SYSTEM….679
(C-10)….681
SHORT IN PUMP MERGE DIVIDER SOLENOID SYSTEM….681
(C-11)….683
OPEN IN PUMP MERGE DIVIDER SOLENOID SYSTEM….683
(C-12)….685
SHORT IN TRAVEL SPEED SOLENOID SYSTEM….685
(C-13)….687
OPEN IN TRAVEL SPEED SOLENOID SYSTEM….687
(C-14)….689
SHORT IN ACTIVE MODE, SWING, SOLENOID SYSTEM….689
(C-15)….691
OPEN IN ACTIVE MODE, SWING, SOLENOID SYSTEM….691
(C-16)….693
ABNORMAL INPUT FOR MODEL CODE….693
(C-17)….695
SHORT IN (LS-EPC) SOLENOID SYSTEM….695
(C-18)….696
OPEN IN (LS-EPC) SOLENOID SYSTEM….696
(C-19)….697
ABNORMAL FRONT PUMP PRESSURE SENSOR SIGNAL….697
(C-20)….699
BINOMIAL REAR PUMP PRESSURE SENSOR SIGNAL….699
(C-21)….701
ABNORMAL PRESSURE SENSOR POWER SUPPLY….701
(C-22)….703
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER….703
(C-23)….705
MACHINE PUSH-UP SOLENOID HAS NO RESPONSE….705
TROUBLESHOOTING ELECTRICAL SYSTEM ON GOVERNOR PUMP CONTROLLER (E-MODE)….708
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM….710
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF….710
USER CODE MEMORY RETENTION FUNCTION….710
INFORMATION CONTAINED IN TESTING PROCEDURES….711
(E-1)….713
CONTROLLER POWER SOURCE (LED) IS OFF….713
(E-2)….715
INCORRECT FUEL CONTROL DIAL VALUE DISPLAYED….715
(E-3)….717
OPEN IN MOTOR DRIVE SYSTEM….717
(E-4)….719
SHORT IN MOTOR DRIVE SYSTEM….719
(E-5)….721
INCORRECT FEEDBACK IN POTENTIOMETER DISPLAYED….721
(E-6)….723
SHORT IN BATTERY RELAY OUTPUT SYSTEM….723
(E-7)….725
ABNORMALITY IN STEP OUT MOTOR SYSTEM….725
(E-8)….727
ENGINE WILL NOT CRANK….727
(E-9)….729
ENGINE SPEED IRREGULAR….729
ENGINE SPEED IS HUNTING….731
(E-10)….733
ENGINE OUTPUT IS LOW….733
(E-11)….735
ENGINE WILL NOT SHUT DOWN….735
(E-12)….737
FAULTY OPERATION OF RELAY OUTPUT SYSTEM….737
TROUBLSHOOTING GOVERNOR, PUMP CONTROLLER, INPUT SIGNAL (F-MODE)….740
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM….741
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF….741
USER CODE MEMORY RETENTION FUNCTION….741
INFORMATION CONTAINED IN TESTING PROCEDURES….742
(F-1)….744
SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP….744
(F-2)….745
TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP….745
(F-3)….746
BOOM (LOWER) PRESSURE SWITCH DOES NOT LIGHT UP….746
(F-4)….747
BOOM (RAISE) PRESSURE SWITCH DOES NOT LIGHT UP….747
(F-5)….748
ARM (IN) PRESSURE SWITCH DOES NOT LIGHT UP….748
(F-6)….749
ARM (OUT) PRESSURE SWITCH DOES NOT LIGHT UP….749
(F-7)….750
BUCKET (CURL) PRESSURE SWITCH DOES NOT LIGHT UP….750
(F-8)….751
BUCKET (DUMP) PRESSURE SWITCH DOES NOT LIGHT UP….751
(F-9)….752
SWING LOCK SWITCH DOES NOT LIGHT UP….752
(F-10)….753
MODE CONNECTION DOES NOT LIGHT UP….753
(F-11)….755
LEFT KNOB SWITCH DOES NOT LIGHT UP….755
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)….758
PUMP MERGE DIVIDER LOGIC….760
SOLENOID ACTUATION TABLE….760
TABLE OF FAILURE MODES AND CAUSES….761
H-1….765
SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER….765
H-2….767
THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS….767
H-3….768
NO WORK EQUIPMENT, TRAVEL, SWING MOVEMENT….768
H-4….769
ABNORMAL NOISE GENERATED AROUND PUMP….769
H-5….770
AUTO DECELERATION DOES NOT WORK WHEN PPC SHUTTLE VALVE IS CAUSE….770
H-6….770
FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR….770
H-7….771
BOOM IS SLOW OR LACKS POWER….771
H-8….773
ARM IS SLOW OR LACKS POWER….773
H-9….775
BUCKET IS SLOW OR LACKS POWER….775
H-10….777
WORK EQUIPMENT; BOOM, ARM, BUCKET, DOES NOT MOVE, BUT TRAVEL AND SWING ARE NORMAL….777
H-11….777
EXCESSIVE HYDRAULIC DRIFT, BOOM, ARM, BUCKET….777
EXCESSIVE HYDRAULIC DRIFT OF BOOM….777
EXCESSIVE HYDRAULIC DRIFT OF ARM OR BUCKET….777
H-12….778
EXCESSIVE TIME LAG, ENGINE AT LOW IDLING….778
H-13….778
OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED….778
H-14….779
IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED….779
H-15….779
MALFUNCTION OF MACHINE PUSH UP FUNCTION….779
H-16….779
IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW….779
H-17….780
IN SWING PLUS BOOM RAISE, BOOM RAISE IS SLOW….780
IN ACTIVE MODE….780
IN OTHER MODE….780
H-18….780
IN SWING PLUS ARM, ARM IS SLOW….780
H-19….780
IN SWING PLUS TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY….780
H-20….781
TRAVEL DEVIATION….781
WHEN THERE IS A DEVIATION IN NORMAL TRAVEL….781
EXCESSIVE DEVIATION WHEN STARTING….781
H-21….783
TRAVEL SPEED IS SLOW….783
H-22….785
STEERING DOES NOT TURN EASILY OR LACKS POWER….785
H-23….787
TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED….787
H-24….787
TRAVEL DOES NOT MOVE, ONE SIDE ONLY….787
H-25….788
DOES NOT SWING….788
DOES NOT SWING TO EITHER LEFT OR RIGHT….788
DOES NOT SWING IN ONE DIRECTION….788
H-26….789
SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW….789
H-27….791
EXCESSIVE OVERRUN WHEN STOPPING SWING….791
ONE DIRECTION ONLY….791
BOTH DIRECTIONS….791
H-28….792
EXCESSIVE SHOCK WHEN STOPPING SWING, ONE DIRECTION ONLY….792
H-29….792
EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING….792
H-30….793
EXCESSIVE HYDRAULIC DRIFT OR SWING….793
WHEN SWING HOLDING BRAKE IS RELEASED….793
WHEN SWING HOLDING BRAKE IS APPLIED….793
H-31….794
SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED….794
TROUBLESHOOTING MACHINE MONITOR SYSTEM (M-MODE)….796
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM….798
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF….798
USER CODE MEMORY RETENTION FUNCTION….798
INFORMATION CONTAINED IN TESTING PROCEDURES….799
(M-1)….801
ERROR IN DATA HISTORY….801
(M-2)….803
SHORT IN BUZZER OUTPUT DISPLAY….803
(M-3)….805
AIR CLEANER CLOG INDICATOR FAILURE….805
(M-4)….807
ABNORMAL ENGINE (HI) OIL PRESSURE….807
(M-5)….809
ENGINE COOLANT INDICATING OVERHEAT CONDITION….809
(M-6)….811
THREE SECOND DELAY ON MONITOR WHEN IGNITION KEY IS TURNED “ON”….811
(M-7)….813
WHEN IGNITION SWITCH IS TURNED “ON” ALL PANEL LAMPS STAY ILLUMINATED….813
(M-8)….813
WHEN IGNITION SWITCH IS TURNED “ON” PANEL LIGHTS DO NOT MATCH THE MACHINE….813
(M-9)….815
ABNORMAL FLUID LEVEL INDICATIONS….815
ENGINE COOLANT LEVEL FLASHES….815
ENGINE OIL LEVEL FLASHES….817
HYDRAULIC OIL LEVEL FLASHES….818
(M-10)….819
PREHEATING INDICATION IS “ON” WHEN SYSTEM IS OFF….819
(M-11)….821
WHEN ENGINE IS STARTED BASIC CHECK ITEMS FLASH….821
ALTERNATOR SYSTEM….821
ENGINE OIL PRESSURE….823
(M-12)….825
WHEN ENGINE IS STARTED CAUTION ITEMS FLASH….825
ALTERNATOR SYSTEM….825
ENGINE OIL PRESSURE….827
(M-13)….829
WHEN THE ENGINE IS STARTED CAUTION AND EMERGENCY ITEMS FLASH….829
ENGINE OIL PRESSURE FLASHES….829
COOLANT LEVEL FLASHES….829
BATTERY CHARGE INDICATOR FLASHES….829
COOLANT TEMPERATURE FLASHES….830
FUEL LEVEL FLASHES….831
AIR CLEANER CLOG INDICATOR FLASHES….832
(M-14)….833
WARNINGS FLASH BUT BUZZER IS DELAYED….833
(M-15)….835
BUZZER SOUNDS CONTINUOUSLY….835
(M-16)….837
NIGHT LIGHT ON MONITOR PANEL DOES NOT LIGHT-UP….837
(M-17)….839
ENGINE COOLANT TEMPERATURE DOES NOT RISE….839
(M-18)….841
ENGINE COOLANT TEMPERATURE GIVES NO DISPLAY….841
(M-19)….843
FUEL LEVEL GAUGE ALWAYS SHOWS “FULL”….843
(M-20)….844
FUEL LEVEL GAUGE DOES NOT DISPLAY….844
(M-21)….845
SWING LOCK NOT INDICATED ON MONITOR WHEN “ON”….845
(M-22)….847
SWING PROLOX NOT INDICATED ON MONITOR….847
(M-23)….849
SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING….849
(M-24)….850
WITH IGNITION SWITCH “OFF”, WHEN THE TIME SWITCH IS PRESSED THE TIME AND SERVICE ARE NOT DISPLAYED….850
(M-25)….851
FAULTY FUEL LEVER SENSOR SYSTEM….851
(M-26)….852
COOLANT TEMPERATURE SENSOR SYSTEM….852
(M-27)….853
FAULTY ENGINE OIL LEVEL SENSOR SYSTEM….853
(M-28)….855
FAULTY ENGINE COOLANT LEVEL SENSOR SYSTEM….855
(M-29)….857
FAULTY HYDRAULIC OIL LEVEL SENSOR SYSTEM….857
(M-30)….859
WIPER DOES NOT WORK, OR REMAINS “ON”….859
WIPER DOES NOT WORK….859
WIPER SWITCH IS IN THE "OFF" POSITION BUT WIPERS REMAIN ON….862
(M-13)….865
WASHER MOTOR WORKS WHEN SWITCH IS NOT BEING USED OR WASHER MOTOR DOES NOT WORK….865
TROUBLESHOOTING COMMUNICATION SYSTEM (N-MODE)….868
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM….869
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF….869
USER CODE MEMORY RETENTION FUNCTION….869
INFORMATION CONTAINED IN TESTING PROCEDURES….870
(N-1)….872
COMMUNICATION ABNORMALITY….872
30 DISASSEMBLY AND ASSEMBLY….874
METHOD OF USING MANUAL….876
PRECAUTIONS DURING OPERATION….877
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK….877
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK….878
PRECAUTIONS WHEN COMPLETING THE OPERATIONS….879
OTHER PRECAUTIONS….879
SPECIAL TOOL LIST….880
SKETCHES OF SPECIAL TOOLS….885
ENGINE….893
AFTERCOOLER….893
ALTERNATOR….893
CYLINDER HEAD….893
ENGINE OIL COOLER….893
ENGINE REAR SEAL….893
FUEL INJECTION PUMP….893
NOZZLE HOLDER….893
STARTING MOTOR….893
THERMOSTAT….893
TURBOCHARGER….893
WATER PUMP….893
GOVERNOR MOTOR….894
OIL COOLER….895
RADIATOR, OIL COOLER….897
ENGINE, MAIN HYDRAULIC PUMP….900
DAMPER….905
FUEL TANK….906
CENTER SWIVEL JOINT….907
FINAL DRIVE….909
TRAVEL MOTOR….920
SPROCKET….934
SWING MOTOR….935
SWING MACHINERY….945
REVOLVING FRAME….954
SWING CIRCLE….956
IDLER AND RECOIL SPRING….957
IDLER….958
RECOIL SPRING….962
TRACK ROLLER….964
CARRIER ROLLER….970
TRACK CHAIN….975
HYDRAULIC TANK….976
MAIN HYDRAULIC PUMP….978
DISASSEMBLY….980
PUMP ASSEMBLY….980
FRONT PUMP….980
REAR PUMP….985
ASSEMBLY….988
FRONT PUMP….988
REAR PUMP….996
MAIN PUMP OIL SEAL….1007
CONTROL VALVE….1008
PUMP MERGE DIVIDER VALVE….1022
PRESSURE COMPENSATION VALVE….1023
FRONT PUMP SERVO VALVE….1024
REAR PUMP SERVO VALVE….1025
LS-EPC SOLENOID VALVE….1026
SOLENOID VALVE….1027
WORK EQUIPMENT PPC VALVE….1029
TRAVEL PPC VALVE….1031
PPC SHUTTLE VALVE….1034
BOOM LOCK VALVE….1037
CYLINDER….1039
BOOM….1039
ARM….1041
BUCKET….1043
HYDRAULIC….1045
BOLT ON TYPE PISTON….1045
THREADED STYLE PISTON….1049
WORK EQUIPMENT….1055
BUCKET….1057
ARM….1059
BUCKET AND ARM….1061
BOOM….1063
OPERATORS CAB….1065
COUNTERWEIGHT….1067
AIR CONDITIONER….1068
COMPRESSOR….1068
CONDENSER….1069
RECEIVER TANK….1070
AIR CONDITIONER UNIT….1071
GOVERNOR, PUMP CONTROLLER….1073
MONITOR PANEL….1074
CONTROL STAND CASE….1075
90 OTHERS….1078
ELECTRICAL….1080
FOLDOUT 1 – CIRCUIT DIAGRAM SHEET 1 (Part 1 of 3)….1080
FOLDOUT 2 – CIRCUIT DIAGRAM SHEET 1 (Part 2 of 3)….1082
FOLDOUT 3 – CIRCUIT DIAGRAM SHEET 1 (Part 3 of 3)….1084
FOLDOUT 4 – CIRCUIT DIAGRAM SHEET 2 (Part 1 of 2)….1086
FOLDOUT 5 – CIRCUIT DIAGRAM SHEET 2 (Part 2 of 2)….1088
FOLDOUT 6 – CIRCUIT DIAGRAM SHEET 3 (Part 1 of 1)….1090
FOLDOUT 7 – ELECTRONIC CONTROL SYSTEM – TOTAL SYSTEM DIAGRAM….1092
HYDRAULIC….1094
FOLDOUT 8 – CIRCUIT DIAGRAM (Sheet 1 of 4)….1094
FOLDOUT 9 – CIRCUIT DIAGRAM (Sheet 2 of 4)….1096
FOLDOUT 10 – CIRCUIT DIAGRAM (Sheet 3 of 4)….1098
FOLDOUT 11 – CIRCUIT DIAGRAM (Sheet 4 of 4)….1100
CLSS OPERATION FOR EACH FUNCTION….1102
FOLDOUT 12 – HYDRAULIC CIRCUIT DIAGRAM….1102
FOLDOUT 13 – WHEN ALL WORK EQUIPMENT IS AT NEUTRAL….1104
FOLDOUT 14 – WHEN PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY….1106
FOLDOUT 15 – WHEN PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY….1108
FOLDOUT 16 – WHEN PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY….1110
FOLDOUT 17 – WHEN PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY….1112
FOLDOUT 18 – WHEN PUMP DIVIDED, TRAVEL OPERATED INDEPENDENTLY….1114
FOLDOUT 19 – WHEN PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY….1116
FOLDOUT 20 – WHEN PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY….1118
FOLDOUT 21 – WHEN PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY….1120
FOLDOUT 22 – WHEN PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY….1122
Komatsu Hydraulic Excavator PC400LC-LK, PC400HD-LK Series Repair Service Manuals