Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC400, PC400LC, PC400HD series, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC400-1, PC400LC-1, PC400-3, PC400LC-3, PC400LC-6, PC400HD-6, PC400LC-8, PC400-7, PC400LC-7 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.
CEAM4006C1 – Hydraulic Excavator PC400LC-6, PC400HD-6 Operation & Maintenance Manual.pdf
CEAM009902 – Hydraulic Excavator PC400LC-8 Operation & Maintenance Manual.pdf
CEAM208040 – Hydraulic Excavator PC400LC-5 with Cummins LTA-10C Engine Operation & Maintenance Manual.pdf
CEAM208505 – Hydraulic Excavator PC400-5 (Mighty), PC400LC-5 (Mighty), PC400HD-5 Operation & Maintenance Manual.pdf
CEBM4006C3 – Hydraulic Excavator PC400LC-6, PC400HD-6 Shop Manual.pdf
CEBM018803 – Hydraulic Excavator PC400LC-8 Shop Manual.pdf
SEAM02080305 – Hydraulic Excavator PC400-3, PC400LC-3 Operation & Maintenance Manual.pdf
SEAM02080502 – Hydraulic Excavator PC400-5, PC400LC-5 Operation & Maintenance Manual.pdf
SEBM0208A03 – Hydraulic Excavator PC400-1, PC400LC-1 Shop Manual.pdf
SEBM037602 – Hydraulic Excavator PC400-7, PC400LC-7 Shop Manual.pdf
SEBM02080307 – Hydraulic Excavator PC400-3, PC400LC-3 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 5,532 pages
File Format: PDF
Language: English
CEAM009902 – Hydraulic Excavator PC400LC-8 Operation & Maintenance Manual….2
INTRODUCTION….4
FOREWORD….5
SAFETY INFORMATION….6
INTRODUCTION….8
Directions Of Machine….8
Visibility From Operator's Seat….9
Proximity Visibility….9
12 m Circumference Visibility….10
Breaking-in The New Machine….11
Product Information….12
Product Identification Number (PIN)/machine Serial No. Plate….12
EPA Regulations, Engine Number Plate….12
Service Meter Location….13
Your Machine Serial Numbers And Distributor….13
TABLE OF CONTENTS….14
SAFETY….22
SAFETY AND WARNING DECALS….23
Location Of The Safety Decals….23
Safety Labels….24
Optional Systems Decal….30
Optional Decal Locations….33
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….34
Precautions Before Starting Operation….34
Ensuring Safe Operation….34
Understanding The Machine….34
Preparations For Safe Operation….34
Precautions Regarding Safety-related Equipment….34
Inspecting Machine….34
SAFETY INFORMATION….34
Safety Rules….34
If Problems Are Found….35
Working Wear And Personal Protective Items….35
Fire Extinguisher And First Aid Kit….35
Safety Equipment….36
Keep Machine Clean….36
Keep Operator's Compartment Clean….36
Precautions When Standing Up From Operator's Seat….36
Leaving Operator's Seat With Lock….37
Emergency Exit From Operator's Cab….37
Handrails And Steps….38
Precautions When Working In High Places….38
Mounting And Dismounting….38
No Persons On Attachments….38
Do Not Get Caught In Articulated Portion….39
Burn Prevention….39
Protection Against Falling Or Flying Objects….39
Fire Prevention And Explosion Prevention….40
Action If Fire Occurs….41
Windshield Washer Fluid….41
Falling Objects, Flying Objects And Intruding Objects Prevention….41
Attachment Installation….42
Attachment Combinations….42
Precautions Related To Cab Glass….42
Unauthorized Modifications….42
Safety At Jobsite….42
Working On Loose Ground….43
Distance To High Voltage Cables….44
Ensure Good Visibility….44
Ventilation For Enclosed Area….45
Signalman's Signal And Signs….45
Asbestos Dust Hazard Prevention….45
SAFETY MACHINE OPERATION….46
Starting Engine….46
Checks Before Starting Engine….46
Safety Rules For Starting Engine….47
Starting Engine In Cold Weather….47
Starting With Booster Cables….47
OPERATION….48
Checks Before Operation….48
Safety Rules For Changing Machine Directions….48
Safety Rules For Traveling….49
Traveling On Slopes….49
Operations On Slopes….50
Prohibited Operations….51
Operations On Snow….52
Parking Machine….53
TRANSPORTATION….54
Loading And Unloading….54
Shipping The Machine….55
TOWING….55
Safety Rules For Towing….55
BATTERY….56
Battery Hazard Prevention….56
LIFTING OBJECTS WITH BUCKET….57
Safety Rules For Lifting Objects….57
SAFETY MAINTENANCE INFORMATION….58
Warning Tag….58
Keep Work Place Clean And Tidy….58
Select Suitable Place For Inspection And Maintenance….58
Only Authorized Personnel….58
Appoint Leader When Working With Others….58
Stop Engine Before Carrying Out Maintenance….59
Two Workers For Maintenance When Engine Is Running….59
Proper Tools….60
Precautions When Working At High Places….60
Accumulator, Gas Spring….61
Personnel….61
Attachments….61
Work Under The Machine….61
Noise….61
When Using Hammer….62
Welding Works….62
Removing Battery Terminals….62
Safety First When Using High-pressure Grease To Adjust Track Tension….62
Do Not Disassemble Recoil Springs….63
Safety Rules For High-pressure Oil….63
Precaution For High Fuel Pressure….63
Safety Handling High-pressure Hoses….64
Precaution For High Voltage….64
Waste Materials….64
Air Conditioner Maintenance….65
Compressed Air….65
Periodic Replacement Of Safety Critical Parts….65
OPERATION….66
MACHINE VIEW ILLUSTRATIONS….67
Overall Machine View….67
Controls And Gauges….68
Machine Monitor….69
DETAILED CONTROLS AND GAUGES….70
Monitoring System….70
Basic Operation Of Machine Monitor….71
Emergency Monitors….76
Caution Monitors….78
Basic Check Monitors….80
Meter Display Portion….82
Gauges And Meter….86
Monitor Switches Portion….90
Maintenance Selector Switch….106
SWITCHES….138
CONTROL LEVERS AND PEDALS….143
SUN ROOF….146
WINDSHIELD….146
EMERGENCY ESCAPE HAMMER….153
DOOR LOCK….153
CAP WITH LOCK….154
DRINK BOX….156
MAGAZINE BOX….156
ASHTRAY….156
AIR CONDITIONER CONTROLS….157
Air Conditioner Control Panel….157
Method Of Operation….162
Automatic Operation….162
Stopping Automatic Operation….163
Manual Operation….163
Stopping Manual Operation….165
Operation With Cold Air To Face And Warm Air To Feet….165
Defroster Operation….167
RADIO….170
Control Panel….170
Controls Of Radio….172
AUXILIARY ELECTRIC POWER….175
24 V Power Source….175
12 V Power Source….175
FUSE….176
FUSIBLE LINK….177
CONTROLLER….177
TOOL BOX….178
GREASE PUMP HOLDER….178
FIRE EXTINGUISHER….178
MACHINE OPERATIONS AND CONTROLS….179
Before Starting Engine….179
Walk-around Checks….179
Checks Before Starting….181
Adjustment….187
Seat Adjustment….187
Adjusting Angle Of Rear View Camera….189
Rear View Mirrors….191
Seat Belt Inspection….194
Seat Belt….195
Operations Before Starting Engine….196
Starting Engine….198
After Starting Engine….201
Breaking-in the New Machine….201
Engine Warm Up….202
Hydraulic System Warm-up….204
Operation After Completion Of Warming-up Operation….210
Stopping The Engine….212
MACHINE OPERATION….213
Preparations For Moving The Machine….213
Moving Machine Forward….214
Moving Machine Backward….215
Stopping Machine….216
Steering The Machine….217
Swinging….219
Work Equipment Controls And Operations….220
Working Mode….222
Prohibited Operations….224
General Operation Information….229
Traveling On Slopes….231
Escape From Mud….233
Recommended Applications….234
BUCKET REPLACEMENT AND INVERSION….236
Replacement….236
Inversion….238
PARKING MACHINE….240
MACHINE INSPECTION AFTER DAILY WORK….242
Locking….242
TRANSPORTATION….243
Transportation Procedure….243
Long Distance Transport Mode….244
Normal Mode Display….244
Long Distance Transport Mode Display….244
Loading And Unloading With Trailer….246
Loading….247
Securing Machine….250
Unloading….253
LIFTING MACHINE….255
TRANSPORTATION POSTURE….257
INCREASING OR REDUCING TRACK FRAME GAUGE….260
COLD WEATHER OPERATION….262
AFTER DAILY WORK COMPLETION….264
AFTER COLD WEATHER SEASON….264
LONG TERM STORAGE….265
Before Storage….265
During Storage….265
After Storage….266
Starting Machine After Long-Term Storage….266
TROUBLES AND ACTIONS….267
Running Out Of Fuel….267
Phenomena That Are Not Failures….268
Towing The Machine….269
Lightweight Towing Hole….270
Severe Job Condition….270
Discharged Battery….271
Starting Engine With Booster Cables….273
OTHER TROUBLE….275
Electrical System….275
Chassis….276
Engine….277
Electronic Control System….278
MAINTENANCE….280
MAINTENANCE INFORMATION….281
OUTLINE OF SERVICE….283
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….283
Oil….283
Fuel….284
Coolant And Water For Dilution….284
Grease….285
Carrying Out KOWA (Komatsu Oil Wear Analysis)….285
KOWA Analysis Items….285
Oil Sampling….286
Storing Oil And Fuel….286
Filters….286
Electric System Maintenance….286
WEAR PARTS….287
Wear Parts List….287
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….288
TIGHTENING TORQUE SPECIFICATIONS….291
Tightening Torque List….291
SAFETY CRITICAL PARTS….292
Safety Critical Parts List….292
MAINTENANCE SCHEDULE….293
Maintenance Schedule Chart….293
Maintenance Interval For Hydraulic Breaker….295
LUBRICATION CHART….296
MAINTENANCE PROCEDURE….296
Initial 1000 Hours Maintenance (Only After The First 1000 Hours)….296
When Required….297
Check, Clean And Replace Air Cleaner Element….297
Clean Inside Of Cooling System….303
Check And Tighten Track Shoe Bolts….307
Check And Adjust Track Tension….308
Replace Bucket Teeth (Vertical Pin Type)….310
Replace Bucket Teeth (Horizontal Pin Type)….313
Replace Bucket Side Cutter, Shroud….315
Adjust Bucket Clearance….316
Check Window Washer Fluid Level, Add Fluid….317
Check And Maintenance Air Conditioner….318
Wash Washable Floor….319
Check Gas Spring….322
Bleeding Air From Hydraulic System….323
Check Before Starting….325
Every 50 Hours Maintenance….326
Lubricating….326
Every 250 Hours Maintenance….327
Lubricate Swing Circle….327
Check Level Of Battery Electrolyte….328
Check Fan Belt, Alternator Belt Tension, Adjust….330
Check Air Conditioner Compressor Belt Tension, Adjust….331
Every 500 Hours Maintenance….332
Lubricating….332
Replace Fuel Pre-filter Cartridge….334
Check Swing Pinion Grease Level, Add Grease….336
Check Oil Level In Swing Machinery Case, Add Oil….337
Check Oil Level In Final Drive Case, Add Oil….338
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge….339
Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins And Condenser Fins….341
Clean Air Conditioner Fresh/recirc Filters….343
Replace Breather Element In Hydraulic Tank….344
Every 1000 Hours Maintenance….345
Replace Fuel Main Filter Cartridge….345
Replace Hydraulic Oil Filter Element….348
Change Oil In Swing Machinery Case….349
Check Oil Level In Damper Case, Add Oil….350
Check All Tightening Points Of Engine Exhaust Pipe Clamps….350
Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)….350
Replace Hydraulic Tank Additional Breather Element….351
Replace Corrosion Resistor Cartridge….352
Every 2000 Hours Maintenance….353
Change Oil In Final Drive Case….353
Clean Hydraulic Tank Strainer….354
Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)….355
Checking Function Of Accumulator….356
Releasing Pressure In Hydraulic Circuit….358
Check Alternator….359
Check Engine Valve Clearance, Adjust….359
Check Vibration Damper….359
Every 4000 Hours Maintenance….360
Check Water Pump….360
Check Starting Motor….360
Replace Accumulator (For Control Circuit)….360
Check For Looseness Of High-pressure Piping Clamp, Hardening Of Rubber….361
Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber….361
Every 5000 Hours Maintenance….362
Change Oil In Hydraulic Tank….362
Every 8000 Hours Maintenance….364
Replace High-pressure Piping Clamp….364
Replace Fuel Spray Prevention Cap….364
SPECIFICATIONS….366
SPECIFICATIONS….367
OPTIONS, ATTACHMENTS….370
GENERAL PRECAUTIONS FOR SAFETY….371
Precautions When Selecting….371
Read The Instruction Manual Thoroughly….371
Precautions When Removing Or Installing….371
Precautions When Using….371
BUCKET WITH HOOK….372
Hook Condition….372
Prohibited Operations….372
MACHINE READY FOR ATTACHMENT….373
Locations….373
ATTACHMENT REMOVAL AND INSTALLATION….383
Attachment Removal….383
Attachment Installation….385
ATTACHMENT OPERATIONS….387
Long Term Storage….388
Specifications….388
HANDLING THE ELECTRIC PRIMING PUMP….389
Bleeding Air From Fuel Circuit….389
ATTACHMENT GUIDE….392
Attachment Combinations….392
Track Shoes Selection….394
Selecting Shoes….394
RECOMMENDED ATTACHMENT OPERATIONS….395
Hydraulic Breaker….395
HANDLING MACHINES EQUIPPED WITH KOMTRAX….400
COUNTERWEIGHT REMOVER….401
Removing the Counterweight….402
Installing the Counterweight….409
CEAM208040 – Hydraulic Excavator PC400LC-5 with Cummins LTA-10C Engine Operation & Maintenance Manual….412
1. FORWARD….414
2. SAFETY INFORMATION….415
3. INTRODUCTION….416
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….417
5. CONTENTS….418
SAFETY….422
6. GENERAL PRECAUTIONS….423
7. PRECAUTIONS DURING OPERATION….429
7.1 BEFORE STARTING ENGINE….429
7.2 OPERATING MACHINE….431
7.3 TRANSPORTATION….437
7.4 BATTERY….438
7.5 TOWING….439
7.6 BUCKET WITH HOOK….440
8. PRECAUTIONS FOR MAINTENANCE….442
8.1 BEFORE CARRYING OUT MAINTENANCE….442
8.2 DURING MAINTENANCE….445
9. POSITION FOR ATTACHING SAFETY LABELS….449
OPERATION….454
10. GENERAL VIEW….455
10.1 GENERAL VIEW OF MACHINE….455
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….456
11. EXPLANATION OF COMPONENTS….457
11.1 ELECTRONIC MONITOR AND CONTROL CONSOLE (EMACC)….457
11.2 METER….466
11.3 SWITCHES….467
11.4 CONTROL LEVERS, PEDALS….473
11.5 CEILING WINDOW….477
11.6 WINDSHIELD….477
11.7 DOOR HOLD OPEN LOCK….479
11.8 CAP, COVER WITH LOCK….479
11.9 DEFROSTER CONTROL….480
11.10 STORAGE TRAY….480
11.11 ASHTRAY….480
11.12 FUSE….481
11.13 FUSIBLE LINK….481
11.14 HANDLING ACCUMULATOR….482
12. OPERATION….483
12.1 CHECK BEFORE STARTING….483
12.2 STARTING ENGINE….497
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….500
12.4 MOVING MACHINE OFF….503
12.5 STEERING THE MACHINE….504
12.6 STOPPING THE MACHINE….505
12.7 SWINGING….506
12.8 OPERATION OF WORK EQUIPMENT….507
12.9 WORKING MODE SELECTION….509
12.10 PROHIBITIONS FOR OPERATION….511
12.11 PRECAUTIONS FOR OPERATION….514
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….515
12.13 HOW TO ESCAPE FROM MUD….516
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR….517
12.15 REPLACEMENT AND INVERSION OF BUCKET….519
12.16 PARKING MACHINE….520
12.17 CHECK AFTER FINISHING WORK….521
12.18 STOPPING ENGINE….521
12.19 CHECK AFTER STOPPING ENGINE….522
12.20 LOCKING AND SECURING MACHINE….523
13. TRANSPORTATION….524
13.1 LOADING AND UNLOADING MACHINE….524
13.2 TRANSPORTING MACHINE….525
13.3 PRECAUTIONS FOR TRANSPORTATION….526
13.4 DISASSEMBLING MACHINE FOR TRANSPORT….526
13.5 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE….529
14. COLD WEATHER OPERATION….531
14.1 PRECAUTIONS FOR LOW TEMPERATURE….531
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….532
14.3 AFTER COLD WEATHER….532
15. LONG-TERM STORAGE….533
15.1 BEFORE STORAGE….533
15.2 DURING STORAGE….535
15.3 AFTER STORAGE….536
15.4 STARTING MACHINE AFrER LONG-TERM STORAGE….536
16. TROUBLESHOOTING….537
16.1 MOVING A DISABLED MACHINE….537
16.2 PRECAUTIONS ON PARTICULAR JOBSITES….538
16.3 IF BAlTERY IS DISCHARGED….539
16.4 STARTING ENGINE WITH BOOSTER CABLE….539
16.5 OTHER TROUBLE….541
16.6 PHENOMENA THAT ARE NOT FAILURES….545
MAINTENANCE….546
17. GUIDES TO MAINTENANCE….547
18. OUTLINES OF SERVICE….550
18.1 OUTLINE OF OIL, FUEL, COOLANT….550
18.2 OUTLINE OF ELECTRICAL SYSTEM….553
18.3 OUTLINE OF HYDRAULIC SYSTEM….554
19. WEAR PARTS LIST….555
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….557
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS….557
20.2 ENGINE OIL SPECIFICATIONS….558
20.3 GREASE SPECIFICATIONS….558
20.4 DIESEL FUEL SPECIFICATIONS….559
20.5 COOLANT SPECIFICATIONS….559
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….564
21.1 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS….564
21.2 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS….564
21.3 TIGHTENING TORQUE FOR NUTS OF FLARED FllTlNGS….565
21.4 UNIT CONVERSIONS….566
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….572
23. MAINTENANCE SCHEDULE CHART….573
24. SERVICE PROCEDURE….576
24.1 SEASONAL PREPARATIONS….576
24.2 AIR CLEANING SYSTEM….577
24.3 AIR CONDITIONER….581
24.4 BELTS….582
24.5 BUCKET….587
24.6 COOLING SYSTEM….593
24.7 ELECTRICAL SYSTEM….599
24.8 ENGINE….602
24.9 ETHER INJECTOR (IF EQUIPPED)….607
24.10 FINAL DRIVE….609
24.11 FUEL SYSTEM….610
24.12 HYDRAULIC SYSTEM….614
24.13 LUBRICATION FITTINGS….627
24.14 PTO CASE….629
24.15 SEAT BELT….629
24.16 SWING MACHINERY….630
24.17 TRACKS….633
24.18 TURBOCHARGER….635
24.19 WALK AROUND INSPECTION….637
24.20 WINDOW WASHER….637
SPECIFICATIONS….638
25. SPECIFICATIONS….639
OPTIONS & ATTACHMENTS….642
26. GENERAL PRECAUTIONS….643
26.1 PRECAUTIONS RELATED TO SAFETY….643
26.2 PRECAUTIONS WHEN INSTALLING AlTACHMENTS….644
27. HANDLING BUCKET WITH HOOK….645
27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK….645
27.2 PROHIBITED OPERATIONS….645
27.3 PRECAUTIONS DURING OPERATIONS….645
28. OPERATING AIR CONDITIONER….646
28.1 CONTROL PANEL….646
28.2 COOLING….647
28.3 HEATING….648
28.4 DEHUMIDIFY AND HEATING….649
29. RADIO….650
29.1 OPERATION….650
29.2 CARE AND MAINTENANCE….650
29.3 TROUBLESHOOTING….650
30. OPTIONAL ELECTRICAL EQUIPMENT….651
30.1 INSTALLATION OF OPTIONAL ELECTRICAL EQUIPMENT….651
30.2 INSTALLATION OF ADDITIONAL LAMPS….652
31. INTRODUCTION OF ATTACHMENTS….653
31.1 BUCKET SELECTION….653
31.2 BUCKET TEETH SELECTION….653
31.3 BUCKET INSTALLATION COMBINATIONS….654
31.4 SELECTION OF TRACK SHOES….655
31.5 HANDLING THE CLAMSHELL BUCKET….656
32. EXTENDING MACHINE SERVICE LIFE….657
32.1 HYDRAULIC BREAKER….657
32.2 CRUSHER….660
32.3 GRAPPLE….661
32.4 BUCKET WITH THUMB GRAPPLE….662
32.5 ROTATING GRAPPLE….663
32.6 SHEAR….664
32.7 HYDRAULIC PILE DRIVER….665
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE….666
CEAM208505 – Hydraulic Excavator PC400-5 (Mighty), PC400LC-5 (Mighty), PC400HD-5 Operation & Maintenance Manual….669
COVER….669
1. FOREWORD….671
2. SAFETY INFORMATION….672
3. INTRODUCTION….673
3.1 INTENDED USE….673
3.2 FEATURES….673
3.3 BREAKING IN THE MACHINE….673
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….674
4.1 MACHINE SERIAL NO. PLATE POSITION….674
4.2 ENGINE SERIAL NO. PLATE POSITION….674
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….674
5. CONTENTS….675
SAFETY….681
6. GENERAL PRECAUTIONS….682
7. PRECAUTIONS DURING OPERATION ….688
7.1 BEFORE STARTING ENGINE ….688
7.2 OPERATING MACHINE ….690
7.3 TRANSPORTATION ….695
7.4 BATTERY ….696
7.5 TOWING….697
7.6 BUCKET WITH HOOK….698
7.6.1 GENERAL PRECAUTIONS….698
7.6.2 PRECAUTIONS FOR LIFTING OPERATION ….700
8. PRECAUTIONS FOR MAINTENANCE ….701
8.1 BEFORE CARRYING OUT MAINTENANCE ….701
8.2 DURING MAINTENANCE ….704
9. POSITION FOR ATTACHING SAFETY LABELS ….708
OPERATION….713
10. GENERAL VIEW ….714
10.1 GENERAL VIEW OF MACHINE ….714
10.2 GENERAL VIEW OF CONTROLS AND GAUGES ….715
11. EXPLANATION OF COMPONENTS ….716
11.1 MACHINE MONITOR ….716
11.2 METER ….726
11.3 SWITCHES ….727
11.4 CONTROL LEVERS, PEDALS ….730
11.5 OPERATOR’S SEAT ….733
11.6 DUST INDICATOR ….733
11.7 CEILING WINDOW ….734
11.8 FRONT WINDOW ….735
11.9 DOOR LOCK ….737
11.10 CAP, COVER WITH LOCK ….738
11.10.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port) ….738
11.10.2 METHOD OF OPENING AND CLOSING HYDRAULIC TANK FILLER CAP open ….738
11.11 RADIO….739
11.11.1 EXPLANATION OF COMPONENTS….739
11.11.2 HOW TO SET STATION SELECTOR BUTTONS ….740
11.11.3 PRECAUTIONS WHEN USING RADIO ….740
11.11.4 TROUBLESHOOTING GUIDE ….740
11.12 FUSE ….741
11.13 MONITOR PANEL ….741
11.14 FUSIBLE LINK ….742
11.15 CONTROLLERS ….742
11.16 HANDLING ACCUMULATOR ….745
11.16.1 METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR ….746
12. OPERATION ….747
12.1 CHECK BEFORE STARTING ENGINE ….747
12.1.1 WALK-AROUND CHECK….747
12.1.2 CHECK BEFORE STARTING ….749
12.1.3 ADJUSTMENT BEFORE OPERATION ….753
12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE ….754
12.2 STARTING ENGINE ….756
12.2.1 NORMAL STARTING ….756
12.2.2 STARTING IN COLD WEATHER ….757
12.2.3 SPECIAL STARTING ….758
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE ….759
12.3.1 WHEN NORMAL….759
12.3.2 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION) ….761
12.4 MOVING MACHINE OFF ….765
12.4.1 MOVING MACHINE FORWARD ….765
12.4.2MOVING MACHINE BACKWARD ….766
12.5 STEERING MACHINE ….768
12.5.1 STEERING (CHANGING DIRECTION) ….768
12.6 STOPPING MACHINE ….770
12.7 SWINGING….771
12.8 OPERATION OF WORK EQUIPMENT ….772
12.9 METHOD OF USING MODE SELECTOR SWITCHES ….773
12.10 PROHIBITIONS FOR OPERATION ….775
12.11 PRECAUTIONS FOR OPERATION ….777
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS ….778
12.13 HOW TO ESCAPE FROM MUD ….780
12.13.1 WHEN ONE SIDE IS STUCK….780
12.13.2 WHEN BOTH SIDES ARE STUCK ….780
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR ….781
12.14.1 BACKHOE WORK ….781
12.14.2 SHOVEL WORK ….781
12.14.3 DITCHING WORK ….781
12.14.4 LOADING WORK ….781
12.15 REPLACEMENT AND INVERSION OF BUCKET ….782
12.15.1 REPLACEMENT….782
12.15.2 INVERSION ….783
12.16 PARKING MACHINE ….784
12.17 CHECK AFTER FINISHING WORK , ….785
12.18 STOPPING ENGINE ….786
12.19 CHECK AFTER STOPPING ENGINE ….787
12.20 LOCKING ….787
13. TRANSPORTATION ….788
13.1 LOADING, UNLOADING WORK ….788
13.2 PRECAUTIONS FOR LOADING ….790
13.3 PRECAUTIONS FOR TRANSPORTATION ….790
13.4 METHOD OF LIFTING CHASSIS (machines equipped with lifting hook) ….791
13.5 DIVING THE MACHINE ….792
13.6 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE ….796
14. COLD WEATHER OPERATION ….798
14.1 PRECAUTIONS FOR LOW TEMPERATURE ….798
14.1.1 FUEL AND LUBRICANTS ….798
14.1.2 COOLANT ….798
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….800
14.3 AFTER COLD WEATHER ….800
15. LONG-TERM STORAGE ….801
15.1 BEFORE STORAGE ….801
15.2 DURING STORAGE ….802
15.3 AFTER STORAGE ….802
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE….802
16. TROUBLESHOOTING ….803
16.1 PHENOMENA THAT ARE NOT FAILURES….803
16.2 METHOD OF TOWING MACHINE ….803
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE ….803
16.4 PRECAUTIONS ON PARTICULAR JOBSITES ….804
16.5 IF BATTERY IS DISCHARGED ….804
165.1 STARTING ENGINE WITH BOOSTER CABLE ….805
16.6 OTHER TROUBLE ….808
16.6.1 ELECTRICAL SYSTEM….808
16.6.2 CHASSIS….809
16.6.3 ENGINE….810
16.6.4 ELECTRONIC CONTROL SYSTEM ….812
MAINTENANCE….813
17. GUIDES TO MAINTENANCE ….814
18. OUTLINES OF SERVICE ….817
18.1 OUTLINE OF OIL, FUEL, COOLANT ….817
18.1.1 OIL….817
18.1.2 FUEL ….818
18.1.3 COOLANT ….818
18.1.4 GREASE ….819
18.1.5 STORING OIL AND FUEL ….819
18.1.6 FILTERS ….819
18.2 OUTLINE OF ELECTRIC SYSTEM ….820
18.3 OUTLINE OF HYDRAULIC SYSTEM ….821
18.4 PRECAUTIONS WHEN DISASSEMBLING MACHINE….822
18.5 BLEEDING AIR FROM CIRCUIT ….823
19. WEAR PARTS LIST ….825
20.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ….827
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….831
21.1 INTRODUCTION OF NECESSARY TOOLS ….831
21.2 TORQUE LIST ….832
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ….833
23. MAINTENANCE SCHEDULE CHART ….835
23.1 MAINTENANCE SCHEDULE CHART ….835
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER ….837
24. SERVICE PROCEDURE ….838
24.1 INITIAL 250 HOURS SERVICE ….838
24.2 WHEN REQUIRED ….839
24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ….839
24.2.2 CLEAN INSIDE OF COOLING SYSTEM ….841
24.2.3 CHECK AND TIGHTEN TRACK SHOE BOLTS ….845
24.2.4 CHECK AND ADJUST TRACK TENSION….846
24.2.5 CHECK ELECTRICAL INTAKE AIR HEATER ….848
24.2.6 REPLACE BUCKET TEETH (VERTICAL PIN TYPE) ….849
24.2.7 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) ….852
24.2.8 ADJUST BUCKET CLEARANCE ….853
24.2.9 CLEAN LINE FILTER….854
24.2.10 DRAIN WATER FROM WATER SEPARATOR ….854
24.3 CHECK BEFORE STARTING ….855
24.3.1 CHECK COOLANT LEVEL, ADD WATER ….855
24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL ….855
24.3.3 CHECK FUEL LEVEL, ADD FUEL ….856
24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ….857
24.3.5 CHECK DUST INDICATOR ….858
24.3.6 CHECK ELECTRIC WIRINGS ….858
24.3.7 LUBRICATE CLAMSHELL BUCKET (12 POINTS) ….859
24.3.8 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER ….859
24.4 EVERY 100 HOURS SERVICE ….860
24.4.1 LUBRICATING 1. ….860
24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL ….862
24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK ….862
24.5 EVERY 250 HOURS SERVICE ….863
24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ….863
24.5.2 CHECK LEVEL OF BAlTERY ELECTROLYTE ….864
24.5.3 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ….865
24.5.4 REPLACE HYDRAULIC FILTER ELEMENT ….866
24.5.5 LUBRICATE SWING CIRCLE (3 POINTS) ….867
24.5.6 CHECK FAN BELT TENSION, ADJUST ….868
24.5.7 DRAIN WATER AND SEDIMENT FROM FUEL FILTER CARTRIDGE ….869
24.5.8 REPLACE HYDRAULIC TANK BREATHER ELEMENT ….869
24.6 EVERY 500 HOURS SERVICE ….870
24.6.1 REPLACE FUEL FILTER CARTRIDGE ….870
24.6.2 CHECK SWING PINION GREASE LEVEL, ADD GREASE ….872
24.6.3 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS ….873
24.7 EVERY 1000 HOURS SERVICE ….874
24.7.1 CHANGE OIL IN SWING MACHINERY CASE ….874
24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ….875
24.7.3 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER ….875
24.7.4 CHECK PLAY OF TURBOCHARGER ROTOR ….875
24.7.5 REPLACE CORROSION RESISTOR CARTRIDGE ….876
24.8 EVERY 2000 HOURS SERVICE ….877
24.8.1 CHANGE OIL IN FINAL DRIVE CASE ….877
24.8.2 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER ….878
24.8.3 CLEAN ENGINE BREATHER ….880
24.8.4 CLEAN, CHECK TURBOCHARGER ….881
24.8.5 CHECK ALTERNATOR, STARTING MOTOR ….881
24.8.6 CHECK ENGINE VALVE CLEARANCE, ADJUST ….881
24.8.7 CHECK VIBRATION DAMPER ….881
24.9 EVERY 4000 HOURS SERVICE ….882
24.9.1 CHECK WATER PUMP ….882
SPECIFICATIONS….883
25. SPECIFICATIONS ….884
OPTIONS, ATTACHMENTS….889
26. GENERAL PRECAUTIONS ….890
26.1 PRECAUTIONS RELATED TO SAFETY ….890
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS ….891
27. HANDLING BUCKET WITH HOOK ….892
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK….892
27.2 PROHIBITED OPERATIONS ….892
27.3 PRECAUTIONS DURING OPERATIONS ….892
28. USING SEAT BELT ….893
28.1 SEAT BELT ….893
28.1.1 FASTEN THE BELT AND REMOVE IT ….893
28.1.2 ADJUST THE BELT LENGTH ….894
29. HANDLING CAR COOLER ….895
29.1 CONTROL PANEL ….895
29.2 CHECKING AND MAINTAINING CAR COOLER ….895
30. HANDLING AIR CONDITIONER ….896
30.1 CONTROL PANEL ….896
30.2 OPERATION ….897
30.3 INSPECTION AND MAINTENANCE ….898
31. OPERATION OF ATTACHMENTS ….900
32. INTRODUCTION OF ATTACHMENTS ….902
32.1 SPECIFICATION, USE ….902
32.2 ATTACHMENT INSTALLATION COMBINATION TABLE ….903
32.3 SELECTION OF TRACK SHOES (EXCEPT PC400,400LC-5 MIGHTY)….904
32.4 SELECTION OF BUCKET TEETH ….905
32.5 HANDLING CLAMSHELL BUCKET ….906
33. EXTENDING MACHINE SERVICE LIFE ….907
33.1 HYDRAULIC BREAKER ….907
33.2 POWER RIPPER ….910
33.3 FORK GRAB ….911
33.4 GRAPPLE BUCKET ….912
33.5 SCRAP GRAPPLE ….913
33.6 CRUSHER AND CUTTER ….914
33.7 HYDRAULIC PILE DRIVER ….915
33.8 HYDRAULIC EXCAVATOR WITH MULTI- PURPOSE CRANE ….916
LOADING SHOVEL….917
34. GENERAL LOCATIONS ….918
35. INSTRUMENTS AND CONTROLS ….919
35.1 SWITCHES ….919
35.2 CONTROL LEVERS, PEDALS ….921
36. PRECAUTIONS FOR MACHINE OPERATION ….923
36.1 PRECAUTIONS DURING OPERATION ….923
37. MAINTENANCE ….926
37.1 EVERY 10 HOURS SERVICE ….926
38. TRANSPORTATION ….927
39. SPECIFICATIONS ….928
CEAM4006C1 – Hydraulic Excavator PC400LC-6, PC400HD-6 Operation & Maintenance Manual….931
INTRODUCTION….935
1. FORWARD….936
2. SAFETY INFORMATION….937
3. INTRODUCTION….938
3.1 INTENDED USE….938
3.2 FEATURES….938
3.3 BREAKING IN A NEW MACHINE….938
4. LOCATION OF PLATES, TABLE TO ENTER….939
4.1 MACHINE SERIAL NO. PLATE POSITION….939
4.2 ENGINE SERIAL NO. PLATE POSITION….939
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….939
5. CONTENTS….940
SAFETY….946
6. GENERAL PRECAUTIONS….947
7. PRECAUTIONS DURING OPERATION….954
7.1 BEFORE STARTING ENGINE….954
7.2 OPERATING MACHINE….956
7.3 TRANSPORTATION….962
7.4 BATTERY….963
7.5 TOWING….964
7.6 BUCKET WITH HOOK….965
7.6.1 GENERAL PRECAUTIONS….965
7.6.2 PRECAUTIONS FOR LIFTING OPERATION….966
8. PRECAUTIONS FOR MAINTENANCE….967
8.1 BEFORE CARRYING OUT MAINTENANCE….967
8.2 DURING MAINTENANCE….970
9. POSITION FOR ATTACHING SAFETY LABELS….974
OPERATION….978
10. GENERAL VIEW….979
10.1 GENERAL VIEW OF MACHINE….979
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….980
11. EXPLANATION OF COMPONENTS….981
11.1 MACHINE MONITOR….981
11.1.1 A. BASIC CHECK ITEMS….981
11.1.2 B. CAUTION ITEMS….983
11.1.3 C. EMERGENCY STOP ITEMS….984
11.1.4 D. METER DISPLAY PORTION….985
11.1.5 E. SWITCHES….988
11.2 SWITCHES….991
11.3 CONTROL LEVERS, PEDALS….995
11.4 CEILING WINDOW….1000
11.5 FRONT WINDOW….1001
11.6 DOOR LOCK….1003
11.7 CAP, COVER WITH LOCK….1004
11.7.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)….1004
11.7.2 METHOD OF OPENING AND CLOSING COVER WITH (For the cover with lock)….1004
11.8 HOT/COOL BOX….1005
11.9 LUGGAGE BOX….1005
11.10 ASHTRAY….1005
11.11 HANDLING AIR CONDITIONER….1006
11.11.1 GENERAL LOCATIONS ON CONTROL PANEL….1006
11.11.2 PRECAUTIONS WHEN USING AIR CONDITIONER….1008
11.12 CAR RADIO….1009
11.12.1 EXPLANATION OF COMPONENTS….1009
11.12.2 LOCATION AND FUNCTION OF CONTROLS….1009
11.12.3 METHOD OF OPERATION….1012
11.12.4 PRECAUTIONS WHEN USING….1013
11.12.5 SPECIFICATIONS….1013
11.13 FUSE….1014
11.14 FUSIBLE LINK….1015
11.15 CONTROLLERS….1015
11.16 TOOL BOX….1015
11.17 GREASE GUN HOLDER….1015
11.18 HANDLING ACCUMULATOR….1016
11.18.1 METHOD OF RELEASING PRESSURE IN CONTROL….1016
12. OPERATION….1017
12.1 CHECK BEFORE STARTING….1017
12.1.1 WALK AROUND CHECK….1017
12.1.2 CHECK BEFORE STARTING….1019
12.1.3 ADJUST BEFORE OPERATION….1024
12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE….1026
12.2 STARTING ENGINE….1028
12.2.1 NORMAL STARTING….1028
12.2.2 STARTING IN COLD WEATHER….1029
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….1031
12.3.1 WHEN NORMAL….1031
12.3.2 IN COLD AREAS….1033
12.4 MOVING MACHINE OFF….1037
12.4.1 MOVING MACHINE FORWARD….1037
12.4.2 MOVING MACHINE BACKWARD….1038
12.5 STEERING MACHINE….1040
12.5.1 STEERING (CHANGING DIRECTION)….1040
12.6 STOPPING MACHINE….1042
12.7 SWINGING….1043
12.8 OPERATION OF WORK EQUIPMENT….1044
12.9 WORKING MODE SELECTION….1045
12.10 PROHIBITIONS FOR OPERATION….1047
12.11 PRECAUTIONS FOR OPERATION….1049
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….1050
12.13 HOW TO ESCAPE FROM MUD….1052
12.13.1 WHEN ONE SIDE IS STUCK….1052
12.13.2 WHEN BOTH SIDES ARE STUCK….1052
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR….1053
12.14.1 BACKHOE WORK….1053
12.14.2 SHOVEL WORK….1053
12.14.3 DITCHING WORK….1053
12.14.4 LOADING WORK….1053
12.15 REPLACEMENT AND INVERSION OF BUCKET….1054
12.15.1 REPLACEMENT….1054
12.15.2 INVERSION….1055
12.16 PARKING MACHINE….1056
12.17 CHECK AFTER FINISHING WORK….1057
12.18 STOPPING ENGINE….1058
12.19 CHECK AFTER STOPPING ENGINE….1059
12.20 LOCKING AND SECURING MACHINE….1059
13. TRANSPORTATION….1060
13.1 LOADING AND UNLOADING MACHINE….1060
13.2 PRECAUTIONS FOR LOADING….1062
13.3 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GUAGE (PC400HD-6 AVANCE)….1063
13.4 PRECAUTIONS FOR TRANSPORTATION….1064
14. COLD WEATHER OPERATION….1065
14.1 PRECAUTIONS FOR LOW TEMPERATURE….1065
14.1.1 FUEL AND LUBRICANTS….1065
14.1.2 COOLANT….1065
14.1.3 BATTERY….1066
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….1067
14.3 AFTER COLD WEATHER….1067
15. LONG-TERM STORAGE….1068
15.1 BEFORE STORAGE….1068
15.2 DURING STORAGE….1069
15.3 AFTER STORAGE….1069
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE….1069
16. TROUBLESHOOTING….1070
16.1 PHENOMENA THAT ARE NOT FAILURES….1070
16.2 METHOD OF TOWING MACHINE….1070
16.3 METHOD FOR USING LIGHT-WEIGHT TOWING HOLE….1070
16.4 PRECAUTIONS ON PARTICULAR JOB SITES….1071
16.5 IF BATTERY IS DISCHARGED….1071
16.5.1 STARTING ENGINE WITH BOOSTER CABLE….1072
16.6 OTHER TROUBLE….1075
16.6.1 ELECTRICAL SYSTEM….1075
16.6.2 CHASSIS….1076
16.6.3 ENGINE….1077
16.6.4 ELECTRONIC CONTROL SYSTEM….1079
MAINTENANCE….1080
17. GUIDES TO MAINTENANCE….1081
18. OUTLINES OF SERVICE….1084
18.1 OUTLINE OF OIL, FUEL, COOLANT….1084
18.1.1 OIL….1084
18.1.2 FUEL….1085
18.1.3 COOLANT….1085
18.1.4 GREASE….1086
18.1.5 STORING OIL AND FUEL….1086
18.1.6 FILTERS….1086
18.2 OUTLINE OF ELECTRIC SYSTEM….1087
18.3 OUTLINE OF HYDRAULIC SYSTEM….1087
18.4 OUTLINE OF FUEL SYSTEM….1088
19. WEAR PARTS LIST….1089
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1091
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS….1091
20.2 ENGINE OIL SPECIFICATIONS….1092
20.3 DIESEL FUEL SPECIFICATIONS….1093
20.4 COOLANT SPECIFICATIONS….1094
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1099
21.1 INTRODUCTION OF NECESSARY TOOLS….1099
21.2 TORQUE LIST….1100
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1101
23. MAINTENANCE SCHEDULE CHART….1103
23.1 MAINTENANCE SCHEDULE CHART….1103
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER….1106
24. SERVICE PROCEDURE….1107
24.1 WHEN REQUIRED….1107
24.1.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1107
24.1.2 CHECK AND TIGHTEN TRACK SHOE BOLTS….1109
24.1.3 CHECK AND ADJUST TRACK TENSION….1110
24.1.4 CHECK ALTERNATOR….1113
24.1.5 CHECK STARTER MOTOR….1113
24.1.6 INSTALLATION OF BUCKET TEETH….1114
24.1.7 ADJUST BUCKET CLEARANCE….1119
24.1.8 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1120
24.1.9 CHECK AND ADJUST AIR CONDITIONER….1121
24.1.10 REPLACE ATTACHMENT RETURN LINE FILTER (OPTION)….1122
24.1.11 CLEAN INLINE FILTER….1123
24.2 CHECK BEFORE STARTING….1124
24.2.1 CHECK COOLANT LEVEL, ADD COOLANT….1124
24.2.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL….1124
24.2.3 CHECK FUEL LEVEL, ADD FUEL….1125
24.2.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….1126
24.2.5 CHECK AIR CLEANER FOR CLOGGING….1127
24.2.6 CHECK ELECTRIC WIRING….1127
24.2.7 DRAIN WATER FROM THE FUEL-WATER SEPARATOR….1127
24.3 EVERY 50 HOURS SERVICE….1128
24.3.1 LUBRICATING….1128
24.4 EVERY 100 HOURS SERVICE….1130
24.4.1 LUBRICATING….1130
24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL….1131
24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK….1131
24.5 EVERY 250 HOURS SERVICE….1132
24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1132
24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE….1133
24.5.3 CHECK AIR INTAKE SYSTEM….1133
24.5.4 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1134
24.5.5 REPLACE HYDRAULIC FILTER ELEMENT….1135
24.5.6 LUBRICATE SWING CIRCLE (3 POINTS)….1136
24.5.7 BELTS, GENERAL….1137
24.5.8 CHECK ALTERNATOR AND FAN BELT TENSION, ADJUST….1138
24.5.9 AIR CONDITIONER COMPRESSOR BELT TENSION….1140
24.5.10 COOLANT ADDITIVE CONCENTRATION….1141
24.5.11 REPLACE FUEL FILTER CARTRIDGES….1141
24.5.12 REPLACE CORROSION RESISTOR CARTRIDGE….1142
24.6 EVERY 500 HOURS SERVICE….1144
24.6.1 CHECK SWING PINION GREASE LEVEL, ADD GREASE….1144
24.6.2 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)….1144
24.6.3 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)….1145
24.6.4 REPLACE HYDRAULIC TANK BREATHER ELEMENT….1145
24.7 EVERY 1000 HOURS SERVICE….1146
24.7.1 CHANGE OIL IN SWING MACHINERY CASE….1146
24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL….1147
24.8 EVERY 1500 HOURS SERVICE….1148
24.8.1 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER….1148
24.8.2 CHECK HOSES, REPLACE….1148
24.8.3 STEAM CLEAN ENGINE….1148
24.8.4 CHECK ENGINE VALVE CLEARANCE, ADJUST….1148
24.9 EVERY 2000 HOURS SERVICE….1149
24.9.1 CHANGE OIL IN FINAL DRIVE CASE….1149
24.9.2 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….1150
24.9.3 CHECK ALTERNATOR, STARTING MOTOR….1154
24.10 EVERY 4000 HOURS SERVICE….1155
24.10.1 CLEAN INSIDE OF COOLING SYSTEM….1155
24.10.2 CHECK WATER PUMP….1160
24.11 EVERY 6000 HOURS SERVICE….1161
24.11.1 CHECK PLAY OF TURBOCHARGER ROTOR….1161
24.11.2 CHECK VIBRATION DAMPER….1161
24.11.3 CHECK FAN HUB….1161
24.11.4 CHECK ENGINE IDLER PULLEY….1161
24.11.5 CHECK FAN PULLEY AND TENSION PULLEY….1161
SPECIFICATIONS….1162
25. SPECIFICATIONS….1163
OPTIONS, ATTACHMENTS….1168
26. GENERAL PRECAUTIONS….1169
26.1 PRECAUTIONS RELATED TO SAFETY….1169
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS….1170
27. HANDLING BUCKET WITH HOOK….1171
27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK….1171
27.2 PROHIBITED OPERATIONS….1171
27.3 PRECAUTIONS DURING OPERATIONS….1171
28. USING SEAT BELT….1172
28.1 SEAT BELT….1172
28.1.1 FASTEN THE BELT AND REMOVE IT….1172
28.1.2 ADJUST THE BELT LENGTH….1173
29. HANDLING CAB HEATER….1174
29.1 EXPLANATION OF COMPONENTS….1174
29.2 PREPARING CAB HEATER….1175
30. HANDLING LARGE CAPACITY CAB HEATER….1176
30.1 EXPLANATION OF COMPONENTS….1176
30.2 PREPARING CAB HEATER….1177
31. MACHINES READY FOR ATTACHMENT….1178
31.1 EXPLANATION OF COMPONENTS….1178
31.2 HYDRAULIC CIRCUIT….1180
31.2.1 CONNECTING HYDRAULIC CIRCUIT….1181
31.3 PROCEDURE FOR REMOVAL AND INSTALLATION OF ATTACHMENT….1182
31.4 OPERATION….1184
31.5 LONG-TERM STORAGE….1185
31.6 SPECIFICATIONS….1185
32. INTRODUCTION OF ATTACHMENTS….1186
32.1 SPECIFICATION, USE….1186
32.2 SPECIFICATION, USE….1187
32.3 ATTACHMENT INSTALLATION COMBINATION TABLE….1188
32.4 ATTACHMENT INSTALLATION COMBINATION TABLE….1189
32.5 SELECTION OF TRACK SHOES….1190
32.6 BUCKET SELECTION….1191
33. EXTENDING MACHINE SERVICE LIFE….1192
33.1 HYDRAULIC BREAKER….1192
33.2 CRUSHER….1195
33.3 GRAPPLE….1196
33.4 BUCKET WITH THUMB GRAPPLE….1197
33.5 ROTATING GRAPPLE….1198
33.6 SHEAR….1199
33.7 HYDRAULIC PILE DRIVER….1200
33.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE….1201
CEBM018803 – Hydraulic Excavator PC400LC-8 Shop Manual….1203
CEBM018803 – PC400LC-8 SN A88001-A88545….1203
CONTENTS….1204
REVISED PAGES….1205
SAFETY….1215
Safety Notice….1215
Important Safety Notice….1215
General Precautions….1215
Preparations For Work….1215
Precautions During Work….1215
GENERAL….1218
HOW TO READ THE SHOP MANUAL….1219
Volumes….1219
Distribution And Updating….1219
Filing Method….1219
Revised Edition Mark….1219
Revisions….1219
Symbols….1219
HOISTING INSTRUCTIONS….1220
Hoisting….1220
Wire Ropes….1220
PUSH PULL COUPLER….1221
Type 1….1221
Disconnection….1221
Connection….1221
Type 2….1222
Disconnection….1222
Connection….1222
Type 3….1223
Disconnection….1223
Connection….1223
EXPLANATION OF MAINTENANCE STANDARD TERMS….1224
STANDARD TIGHTENING TORQUE….1226
Bolts And Nuts….1226
Tightening Torque Of Hose Nuts….1227
Tightening Torque Of Split Flange Bolts….1227
Tightening Torque For Flared Nuts….1227
Tightening Torques For O-ring Boss Piping Joints….1228
Table Of Tightening Torques For O-ring Boss Plugs….1228
Torque Table For Hoses (Taper Seal Type And Face Seal Type)….1228
ELECTRIC WIRE CODE….1229
Classification By Thickness….1229
Classification By Color And Code….1229
How To Read Electric Wire Code….1230
CONVERSION TABLES….1233
Method Of Using The Conversion Table….1233
COATING MATERIALS….1239
01 GENERAL….1241
SPECIFICATION DIMENSION DRAWINGS….1242
Dimensions….1242
Working Ranges….1243
SPECIFICATIONS….1244
WEIGHT TABLE….1248
FUEL, COOLANT AND LUBRICANTS….1250
Lubrication Chart….1252
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD….1253
ENGINE AND COOLING SYSTEM….1256
Engine Related Parts….1256
Radiator, Oil Cooler And Aftercooler….1257
POWER TRAIN….1259
Power Train….1259
Final Drive….1260
Sprocket….1262
Swing Machinery….1264
Swing Circle….1266
UNDERCARRIAGE AND FRAME….1268
Track Frame And Recoil Spring….1268
Idler….1270
Carrier Roller….1272
Track Roller….1274
Triple Grouser Shoe….1278
HYDRAULIC SYSTEM….1280
Hydraulic Piping Drawing….1280
Hydraulic Tank And Filter….1282
Hydraulic Pump….1284
LS Valve….1290
PC Valve….1295
LS(PC)-EPC Valve….1303
Variable Volume Valve….1306
Control Valve….1308
CLSS (Closed Center Load Sensing System)….1320
Functions And Operation By Valve….1324
Unload Valve….1326
LS Bypass Valve….1329
Pressure Compensation Valve….1330
Pressure Compensation Valve Inner Shuttle Valve….1333
Boom Regeneration Circuit….1335
Arm Regeneration Circuit….1337
Merge-Divider Valve….1339
LS Select Valve….1341
Self Pressure Reducing Valve….1342
Travel Junction Valve….1345
Travel PPC Shuttle Valve….1347
Boom Drift Preventive Valve….1349
Arm Drift Preventive Valve….1352
Quick Return Valve….1356
Lift Check Valve….1358
Main Relief Valve….1359
2-Stage Safety-Suction Valve….1360
Variable Pressure Compensation Valve….1362
Attachment Circuit Selector Valve….1364
Holding Valve….1366
Valve Control….1371
PPC Valve….1372
Travel PPC Valve….1378
Service PPC Valve (With EPC Valve)….1388
Solenoid Valve….1390
PPC Accumulator….1392
Return Oil Filter….1393
Center Swivel Joint….1394
Travel Motor….1396
Brake Valve….1404
Swing Motor….1410
Reverse Prevention Valve….1416
Hydraulic Cylinder….1420
Boom Cylinder….1420
Arm Cylinder….1420
Bucket Cylinder….1420
WORK EQUIPMENT….1422
Work Equipment….1422
Dimensions Of Components….1424
Dimension Of Arm….1424
Dimension Of Bucket….1426
AIR CONDITIONER PIPING….1428
ELECTRICAL SYSTEM….1429
Engine Control….1429
Fuel Control Dial….1431
Engine Controller….1432
Sensors….1436
Rotation Sensor….1436
Oil Pressure Switch….1436
Ambient Pressure Sensor….1437
Boost Pressure Sensor….1437
Boost Temperature Sensor….1438
Coolant Temperature Sensor….1438
Hydraulic Oil Temperature Sensor….1438
EGR Valve Stroke Sensor….1439
Engine Oil Level Sensor….1440
ELECTRONIC CONTROL SYSTEM….1441
Engine And Pump Composite Control Function….1444
Pump And Valve Control….1450
2-Stage Relief Function….1451
Power Maximizing And Machine Push-up….1452
Auto-Deceleration….1454
Auto-Warm-Up And Overheat Prevention….1456
Swing Control….1458
Travel Control….1460
Attachment Flow Control And Circuit Selector….1462
System Component Parts….1463
PPC Oil Pressure Switch….1463
Oil Pressure Sensor….1464
Pump Pressure Sensor (High Pressure)….1465
Pump Controller….1466
MONITOR SYSTEM….1469
Machine Monitor….1470
Monitor Control, Display Portion….1474
Monitor Items And Display….1476
Switches….1480
Komtrax Logic….1491
Sensors….1498
KOMTRAX TERMINAL SYSTEM….1501
Komtrax Communication Modem – TH300….1502
20 STANDARD VALUE TABLES….1505
STANDARD VALUE TABLES….1506
Engine Related….1506
Chassis Related….1507
30 TESTING AND ADJUSTING….1515
SERVICE TOOLS….1517
Sketches Of Special Tools….1522
ENGINE….1523
Engine Speed….1523
Air Boost Pressure….1525
Exhaust Temperature….1526
Exhaust Gas Color….1527
Valve Clearance….1529
Compression Pressure….1531
Blow-By Pressure….1534
Engine Oil Pressure….1535
EGR Valve Drive Pressure….1536
Handling Fuel System Parts….1537
Releasing Residual Pressure From Fuel System….1537
Fuel Pressure….1538
Cylinder Cut-Out Operation….1539
No Injection Cranking Operation….1539
Fuel Return Rate And Leakage….1540
Bleeding Air From Fuel Circuit….1543
Fuel Circuit, Checking For Leakage….1545
FAN BELT AND ALTERNATOR BELT TENSION….1546
AIR CONDITIONER COMPRESSOR BELT TENSION….1547
SWING CIRCLE BEARING CLEARANCE….1548
TRACK SHOE TENSION….1549
OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS….1550
CONTROL CIRCUIT – BASIC PRESSURE….1556
PUMP PC CONTROL CIRCUIT….1557
PUMP LS CONTROL CIRCUIT….1561
SOLENOID VALVE – OUTPUT PRESSURE….1566
PPC VALVE – OUTPUT PRESSURE….1569
WORK EQUIPMENT PPC VALVE AND SWING PPC VALVE – PLAY ADJUSTMENT….1571
WORK EQUIPMENT – HYDRAULIC DRIFT – CAUSE….1572
HYDRAULIC CIRCUIT – RELEASING REMAINING PRESSURE….1574
Oil Leakage Measurement….1575
BLEEDING AIR FROM VARIOUS PARTS….1578
MACHINE MONITOR – SPECIAL FUNCTIONS….1581
Ordinary Functions And Special Functions Of Machine Monitor….1583
Operator Mode (Outline)….1585
Display Of Komatsu Logo….1586
Display Of Inputting Password….1586
Display Of Check Of Breaker Mode….1587
Display Of Check Before Starting….1587
Display Of Warning After Check Before Starting….1587
Display Of Ending Of Maintenance Interval….1588
Display Of Check Of Working Mode And Travel Speed….1588
Display Of Ordinary Screen….1588
Display Of End Screen….1589
Selection Of Auto-Deceleration….1589
Selection Of Working Mode….1589
Selection Of Travel Speed….1590
Operation To Stop Alarm Buzzer….1590
Operation Of Windshield Wiper….1591
Operation Of Window Washer….1591
Operation Of Air Conditioner/Heater….1591
Operation To Display Camera Mode (If Camera Is Installed)….1592
Operation To Display Clock And Service Meter….1593
Check Of Maintenance Information….1593
Setting And Display Of User Mode….1593
KOMTRAX Message….1594
Display Of Energy-Saving Guidance….1594
Display Of Caution Monitor….1594
Display Of Automatic Judgment Of Breaker….1595
Display Of User Code And Failure Code….1595
Function Of Checking Display Of LCD (Liquid Crystal Display)….1597
Function Of Checking Service Meter….1597
Function Of Changing Attachment/Maintenance Password….1598
Service Mode….1601
Monitoring….1603
Abnormality Record (Mechanical Systems)….1607
Abnormality Record (Electrical Systems)….1608
Abnormality Record (Air-Conditioning System/Heater System)….1614
Maintenance Record….1615
Maintenance Mode Change….1616
Phone Number Entry….1619
Default (Key-On Mode)….1620
Default (Unit)….1621
Default (With/Without Attachment)….1622
Default (Attachment/Maintenance Password)….1623
Default (Camera)….1624
Default (ECO Display)….1625
Default (Breaker Detect)….1627
Adjustment (Pump Absorption Torque (F))….1628
Adjustment (Pump Absorption Torque (R))….1629
Adjustment (Low Speed)….1630
Adjustment (Attachment Flow Adjustment)….1631
Determining A Defective Cylinder….1632
Cylinder Cut-Out….1633
No Injection….1634
Fuel Consumption….1636
KOMTRAX Settings (Terminal Status)….1637
Long Distance Transport Mode….1638
KOMTRAX Settings (GPS & Communication Status)….1640
KOMTRAX Setting (Modem S/N: TH300)….1641
Display Of KOMTRAX Message….1642
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER….1643
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM….1644
DIODE INSPECTION PROCEDURES….1649
PM CLINIC SERVICE….1650
40 TROUBLESHOOTING….1659
FAILURE CODES TABLE….1663
FUSE LOCATIONS….1666
Connection Table Of Fuse Box….1666
Location Of Fuse Box And Fuse Numbers….1667
GENERAL INFORMATION….1670
Points To Remember When Troubleshooting….1670
Sequence Of Events In Troubleshooting….1672
Handling Electric Equipment And Hydraulic Components….1673
Connectors Newly Used For Tier 3 Engines….1681
Checks Before Troubleshooting….1685
Classification And Troubleshooting Steps….1686
Classification Of Troubleshooting….1686
Information In Troubleshooting Table….1688
Possible Problems And Troubleshooting No….1690
Connection Table For Connector Pin Numbers….1693
T-adapter Box And T-adapter Table….1728
FAILURE CODE (DISPLAY OF CODE)….1731
989L00 – Engine Controller Lock Caution 1….1731
989M00 – Engine Controller Lock Caution 2….1731
989N00 – Engine Controller Lock Caution 3….1732
AA10NX – Air Cleaner Clogging….1734
AB00KE – Charge Voltage Low….1736
B@BAZG – Engine Oil Pressure Low….1738
B@BAZK – Engine Oil Level Low….1740
B@BCNS – Engine Coolant Overheat….1742
B@BCZK – Engine Coolant Level Low….1744
B@HANS – Hydraulic Oil Overheat….1746
CA111 – EMC Critical Internal Failure….1748
CA115 – Engine Ne And Bkup Speed Sensor Error….1750
CA122 – Charge Air Pressure Sensor High Error….1752
CA123 – Charge Air Pressure Sensor Low Error….1754
CA131 – Throttle Sensor High Error….1756
CA132 – Throttle Sensor Low Error….1758
CA135 – Engine Oil Pressure Sensor High Error….1760
CA141 – Engine Oil Pressure Sensor Low Error….1762
CA144 – Coolant Temperature Sensor High Error….1764
CA145 – Coolant Temperature Sensor Low Error….1766
CA153 – Charge Air Temperature Sensor High Error….1768
CA154 – Charge Air Temperature Sensor Low Error….1770
CA187 – Sensor Power Supply 2 Volt Low Error….1772
CA221 – Ambient Pressure Sensor High Error….1774
CA222 – Ambient Pressure Sensor Low Error….1776
CA227 – Sensor Supply 2 Volt High Error….1778
CA234 – Engine Overspeed….1780
CA238 – NE Speed Sensor Supply Voltage Error….1781
CA263 – Fuel Temperature Sensor High Error….1782
CA265 – Fuel Temperature Sensor Low Error….1784
CA271 – IMV/PCV1 Short Error….1785
CA272 – IMV/PCV1 Open Error….1786
CA273 – PCV2 Short Error….1787
CA274 – PCV2 Open Error….1788
CA322 – Injector #1 Open/short Error….1790
CA323 – Injector #5 Open/short Error….1792
CA324 – Injector #3 Open/short Error….1794
CA325 – Injector #6 Open/short Error….1796
CA331 – Injector #2 Open/short Error….1798
CA332 – Injector #4 Open/short Error….1800
CA342 – Calibration Code Incompatibility….1802
CA351 – Injectors Drive Circuit Error….1804
CA352 – Sensor Supply 1 Volt Low Error….1806
CA386 – Sensor Supply 1 Volt High Error….1808
CA441 – Battery Voltage Low Error….1810
CA442 – Battery Voltage High Error….1812
CA449 – Rail Pressure Very High Error….1814
CA451 – Rail Pressure Sensor High Error….1818
CA452 – Rail Pressure Sensor Low Error….1820
CA553 – Rail Pressure High Error….1822
CA554 – Rail Pressure Sensor In Range Error….1823
CA559 – Rail Pressure Low Error….1824
CA689 – Engine Ne Speed Sensor Error….1828
CA731 – Engine Bkup Speed Sensor Phase Error….1830
CA757 – All Persistent Data Lost Error….1832
CA778 – Engine Bkup Speed Sensor Error….1834
CA1228 – EGR Valve Servo Error 1….1836
CA1625 – EGR Valve Servo Error 2….1837
CA1633 – KOMNET Datalink Timeout Error….1838
CA2185 – Throttle Sensor Supply Volt High Error….1840
CA2186 – Throttle Sensor Supply Volt Low Error….1842
CA2249 – Rail Pressure Very Low Error….1843
CA2272 – EGR Valve Lift Sensor Low Error….1846
CA2351 – EGR Valve Solenoid Operation Short Circuit….1848
CA2555 – Grid Htr Relay Volt High Error….1852
CA2556 – Grid Htr Relay Volt Low Error….1854
D110KB – Battery Relay Drive Short Circuit….1856
D19JKZ – Personal Code Relay Abnormality….1858
D862KA – GPS Antenna Discon….1860
DA22KK – Pump Solenoid Power Low Error….1862
DA25KP – 5 V Sensor Power Supply Output 1 Abnormality….1864
DA29KQ – Model Selection Abnormality….1868
DA2RMC – CAN Discon (Pump Con Detected)….1870
DAF8KB – Short circuit in camera power supply….1872
DAFGMC – GPS Module Error….1874
DAFRMC – CAN Discon (Monitor Detected)….1876
DGH2KB – Hyd Oil Sensor Short….1878
DHPAMA – F Pump Pressure Sensor Abnormality….1880
DHPBMA – R Pump Pressure Sensor Abnormality….1883
DHS3MA – Arm Curl In PPC Sensor Abnormality….1886
DHS4MA – Bucket Curl PPC Pressure Sensor Abnormality….1888
DHX1MA – Overload Sensor Abnormality (Analog)….1890
DW43KA – Travel Speed Solenoid Disconnection….1892
DW43KB – Travel Speed Solenoid Short Circuit….1894
DW45KA – Swing Brake Solenoid Disconnection….1896
DW45KB – Swing Brake Solenoid Short Circuit….1900
DW91KA – Travel Junction Solenoid Disconnection….1902
DW91KB – Travel Junction Solenoid Short Circuit….1904
DWA2KA – Attachment Sol Open Circuit….1906
DWA2KB – Attachment Sol Short Circuit….1908
DWJ0KA – Merge-divider Solenoid Disconnection….1910
DWJ0KB – Merge-divider Solenoid Short Circuit….1912
DWK0KA – 2-stage Relief Solenoid Disconnection….1914
DWK0KB – 2-stage Relief Solenoid Short Circuit….1916
DXA0KA – PC-EPC Solenoid Disconnection….1918
DXA0KB – PC-EPC Solenoid Short Circuit….1920
DXE0KA – LS-EPC Solenoid Disconnection….1922
DXE0KB – LS-EPC Solenoid Short Circuit….1924
DXE4KA – Service Current EPC Disconnection….1926
DXE4KB – Service Current EPC Short Circuit….1927
DY20KA – Wiper Working Abnormality….1928
DY20MA – Wiper Parking Abnormality….1930
DY2CKA – Washer Drive Open Circuit….1932
DY2CKB – Washer Drive Short Circuit….1934
DY2DKB – Wiper Drive (Fwd) Short Circuit….1936
DY2EKB – Wiper Drive (Rev) Short Circuit….1938
E-MODE (ELECTRICAL SYSTEM)….1940
Before Carrying Out Troubleshooting Of Electrical System….1940
Information Contained In Troubleshooting Table….1942
E-1 Engine Does Not Start….1944
E-2 Auto-decelerator Does Not Operate….1948
E-3 Automatic Warming-up System Does Not Operate….1950
E-4 Preheater Does Not Operate….1952
E-5 All Work Equipment, Swing, And Travel Mechanism Do Not Move….1954
E-6 Power Maximizing Function Does Not Operate….1956
E-7 Machine Monitor Does Not Display At All….1958
E-8 Machine Monitor Does Not Display Some Items….1960
E-9 Contents Of Display By Machine Monitor Are Different From Applicable Machine….1960
E-10 Fuel Level Monitor Was Lighted In Red While Engine Running….1961
E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally….1962
E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally….1964
E-13 Fuel Level Gauge Does Not Indicate Normally….1965
E-14 Swing Lock Monitor Does Not Indicate Normally….1966
E-15 When Monitor Switch Is Operated, Monitor Displays Nothing….1968
E-16 Windshield Wiper And Window Washer Do Not Operate….1970
E-17 Machine Push-up Function Does Not Operate Normally….1974
E-18 Monitoring Function Fails To Display “Boom Raise” Normally….1976
E-19 Monitoring Function Fails To Display “Boom Lower” Normally….1978
E-20 Monitoring Function Fails To Display “Arm In” Normally….1980
E-21 Monitoring Function Fails To Display “Arm OUT” Normally….1982
E-22 Monitoring Function Fails To Display “Bucket CURL” Normally….1984
E-23 Monitoring Function Fails To Display “Bucket DUMP” Normally….1986
E-24 Monitoring Function Fails To Display “Swing” Normally….1988
E-25 Monitoring Function Fails To Display “Travel” Normally….1990
E-26 Monitoring Function Fails To Display “Travel Differential Pressure” Normally….1992
E-27 Monitoring Function Fails To Display “Service” Normally….1994
E-28 KOMTRAX System Does Not Operate Normally….1996
E-29 Air Conditioner Does Not Operate….1998
E-30 Travel Alarm Does Not Sound Or Does Not Stop Sounding….2000
E-31 Horn Does Not Sound….2002
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)….2004
System Chart For Hydraulic And Mechanical System….2004
Information Contained In Troubleshooting Table….2006
H-1 All Work Equipment Lack Power, Or Travel And Swing Speeds Are Slow….2008
H-2 Engine Speed Sharply Drops Or Engine Stalls….2010
H-3 No Work Equipment, Swing Or Travel Move….2011
H-4 Abnormal Noise Is Heard From Around Hydraulic Pump….2011
H-5 Auto-decelerator Does Not Work….2012
H-6 Fine Control Mode Does Not Function Or Responds Slow….2012
H-7 Boom Moves Slowly Or Lacks Power….2013
H-8 Arm Moves Slowly Or Lacks Power….2014
H-9 Bucket Moves Slowly Or Lacks Power….2015
H-10 Work Equipment Does Not Move In Individual Operation….2015
H-11 Work Equipment Has A Bit Too Fast Hydraulic Drift….2016
H-12 Work Equipment Has Long Time Lag….2018
H-13 Other Work Equipment Moves When Relieving Single Circuit….2018
H-14 Power Max. Switch Does Not Operate….2019
H-15 Machine Push-up Function Does Not Operate….2019
H-16 In Compound Operation Of Work Equipment, Speed Of Part Loaded More Is Low….2020
H-17 In Swing + Boom Raise Operation, Boom Moves Slowly….2020
H-18 In Swing + Travel Operation, Travel Speed Drops Sharply….2020
H-19 Machine Swerves In Travel….2021
H-20 Machine Travels Slowly….2022
H-21 Machine Cannot Be Easily Steered Or Lacks Power….2023
H-22 Travel Speed Does Not Shift, Or It Is Too Slow Or Fast….2024
H-23 Travel System Does Not Turn (On One Side Only)….2025
H-24 Machine Does Not Swing….2026
H-25 Swing Acceleration Is Poor, Or Swing Speed Is Slow….2028
H-26 Excessive Overrun When Stopping Swing….2030
H-27 There Is Big Shock When Stopping Swing….2031
H-28 Large Sound Is Made When Upper Structure Stops Swinging….2031
H-29 Swing Hydraulic Drift Is Too Big….2032
H-30 Attachment Circuit Is Not Changed….2033
H-31 Oil Flow In Attachment Circuit Cannot Be Controlled….2034
50 DISASSEMBLY AND ASSEMBLY….2035
HOW TO READ THIS MANUAL….2039
SPECIAL TOOLS LIST….2042
SKETCHES OF SPECIAL TOOLS….2046
CONNECTOR REPAIR PROCEDURES….2051
Contact Terminal Removal (HD30 Type)….2051
Striping Insulation….2052
Crimping Contact Terminal (HD30 Type)….2053
Insertion Of Contact Terminal (HD30 Type)….2054
Contact Terminal Removal (DT Type)….2055
Striping Insulation….2056
Crimping Contact Terminal (DT Type)….2057
Insertion Of Contact Terminal (DT Type)….2058
ENGINE COMPONENTS….2059
Fuel Supply Pump….2059
Removal….2059
Installation….2063
Fuel Injector….2065
Removal….2065
Installation….2069
Engine Front Seal….2073
Removal….2073
Installation….2075
Engine Rear Seal….2076
Removal….2076
Installation….2078
Cylinder Head….2081
Removal….2081
Installation….2090
Oil Pan Gasket….2094
RADIATOR….2095
Removal….2095
Installation….2096
HYDRAULIC OIL COOLER….2097
Removal….2097
Installation….2098
AFTERCOOLER….2099
Removal….2099
Installation….2100
ENGINE AND HYDRAULIC OIL PUMP….2101
Removal….2101
Installation….2110
DRIVE ASSEMBLY….2111
Removal….2111
Installation….2111
Disassembly….2112
Assembly….2117
SWING MOTOR AND SWING MACHINERY….2123
Removal….2123
Installation….2124
Disassembly….2125
Assembly….2129
SWING CIRCLE….2135
Removal….2135
Installation….2135
CARRIER ROLLER….2136
Assembly….2136
TRACK ROLLER….2138
Assembly….2138
IDLER….2139
Disassembly….2139
ASSEMBLY….2140
RECOIL SPRING….2143
Disassembly….2143
Assembly….2144
SPROCKET….2146
Removal….2146
Installation….2146
TRACK SHOE….2147
Expansion Of Track Shoe….2147
Installation Of Track Shoe….2148
REVOLVING FRAME….2149
Removal….2149
Installation….2150
COUNTERWEIGHT….2152
Removal….2152
Installation….2153
COUNTERWEIGHT REMOVER….2154
Removing….2155
Installing….2161
CENTER SWIVEL JOINT….2163
Removal….2163
Installation….2164
Disassembly….2165
Assembly….2166
HYDRAULIC TANK….2167
Removal….2167
Installation….2168
CONTROL VALVE….2169
Removal….2169
Installation….2172
Disassembly….2173
Assembly….2175
HYDRAULIC PUMP….2178
Removal….2178
Installation….2180
HYDRAULIC PUMP INPUT SHAFT OIL SEAL….2181
Removal….2181
Installation….2181
WORK EQUIPMENT PPC VALVE….2182
Disassembly….2182
Assembly….2182
TRAVEL PPC VALVE….2184
Disassembly….2184
Assembly….2185
HYDRAULIC CYLINDER….2187
Disassembly….2187
Assembly….2190
WORK EQUIPMENT….2193
Removal….2193
Installation….2195
CAB….2196
Removal….2196
Installation….2199
Cab Glass (Stuck Glass)….2200
Removal….2201
Installation….2202
Front Window….2211
Removal….2211
Installation….2213
Floor Frame….2219
Removal….2219
Installation….2223
ELECTRICAL SYSTEMS….2224
Air Conditioner Unit….2224
Removal….2224
Installation….2228
KOMTRAX Communication Modem….2229
Removal….2229
Installation….2229
Monitor….2230
Removal….2230
Installation….2231
Pump Controller….2232
Removal….2232
Installation….2232
Engine Controller….2235
Removal….2235
Installation….2236
90 DIAGRAMS AND DRAWINGS….2237
Hydraulic circuit diagram….2239
Electrical circuit diagram (1/5)….2240
Electrical circuit diagram (2/5)….2241
Electrical circuit diagram (3/5)….2242
Electrical circuit diagram (4/5)….2243
Electrical circuit diagram (5/5)….2244
Connector list and stereogram….2245
CEBM4006C3 – Hydraulic Excavator PC400LC-6, PC400HD-6 Shop Manual….2246
CONTENTS….2247
01 GENERAL….2269
SPECIFICATION DRAWINGS….2270
SPECIFICATIONS….2274
WEIGHT TABLE….2276
FUEL, COOLANT AND LUBRICANTS….2278
ENGINE OIL SPECIFICATIONS….2281
DIESEL FUEL SPECIFICATIONS….2282
COOLANT SPECIFICATIONS….2283
10 STRUCTURE AND FUNCTION….2287
PARTS RELATED TO ENGINE….2288
RADIATOR, OIL COOLER….2290
POWER TRAIN….2291
FINAL DRIVE….2292
SWING CIRCLE….2293
SWING MACHINERY….2294
TRACK FRAME, RECOIL SPRING – PC400LCC-6….2295
TRACK FRAME, RECOIL SPRING FOLDOUT – PC400HD-6….2296
TRACK SHOE….2297
HYDRAULIC PIPING DRAWING….2298
HYDRAULIC CIRCUIT DRAWING….2299
HYDRAULIC TANK, HYDRAULIC FILTER….2300
HYDRAULIC PUMP….2301
CONTROL VALVE….2322
SUCTION SAFETY VALVE….2331
CLSS….2332
SWING MOTOR….2365
CENTER SWIVEL JOINT….2369
TRAVEL MOTOR….2370
VALVE CONTROL….2379
WORK EQUIPMENT, SWING PPC VALVE….2380
TRAVEL PPC VALVE….2384
SERVICE PPC VALVE….2388
PPC SAFETY LOCK VALVE….2391
PCC ACCUMULATOR….2391
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE….2392
EPC SOLENOID VALVE….2399
BOOM HOLDING VALVE….2404
HYDRAULIC CYLINDER….2407
WORK EQUIPMENT….2408
ACTUAL ELECTRIC WIRING DIAGRAM….2409
ELECTICAL CIRCUIT DIAGRAM….2419
ENGINE CONTROL….2422
ELECTRICAL CONTROL SYSTEM….2429
MACHINE MONITOR SYSTEM….2452
20 TESTING AND ADJUSTMENT….2459
STANDARD VALUE TABLE FOR ENGINE….2460
STANDARD VALUE TABLE FOR CHASSIS PARTS….2461
STANDARD VALUE TABLE FOR ELECTRICAL PARTS….2469
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING….2477
MEASURING ENGINE SPEED….2478
MEASURING INTAKE MANIFOLD PRESSURE….2479
MEASURING INTAKE AIR RESTRICTION….2479
MEASURING LUBRICATING OIL PRESSURE….2479
MEASURING FUEL (FILTER) INLET RESTRICTION….2479
MEASURING BLOWBY PRESSURE….2480
MEASURING ENGINE BACK PRESSURE….2480
MEASURING EXHAUST COLOR….2480
MEASURING COOLANT TEMPERATURE….2481
MEASURING VALVE CLEARANCE….2481
BELT TENSION….2482
GOVERNOR MOTOR LEVER STROKE….2483
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT….2484
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)….2487
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTAIL PRESSURE….2489
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE….2492
TESTING SOLENOID VALVE OUTPUT PRESSURE….2494
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE….2496
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE….2498
TESTING TRAVEL DEVIATION….2499
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT….2500
MEASURING OIL LEAKAGE….2502
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT….2504
TESTING CLEARANCE OF SWING CIRCLE BEARING….2505
TESTING AND ADJUSTING TRACK SHOE TENSION….2506
BLEEDING AIR….2507
TROUBLESHOOTING….2509
POINTS TO REMEMBER WHEN TROUBLESHOOTING….2510
SEQUENCE OF EVENTS IN TROUBLESHOOTING….2511
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….2512
CHECKS BEFORE TROUBLESHOOTING….2521
CONNECTOR TYPES AND MOUNTING LOCATIONS….2522
CONNECTOR ARRANGEMENT DIAGRAM….2526
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….2535
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM….2546
DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL….2547
METHOD OF USING JUDGEMENT TABLE….2555
METHOD OF USING TROUBLESHOOTING CHARTS….2557
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE….2559
SERVICE CODE TABLE….2564
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)….2565
N-1 [E218] Communication abnormality….2566
TROUBLESHOOTING OF GOVERNOR PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)….2568
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM….2569
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE….2570
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND RELATED PARTS….2574
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM….2576
E-1 Abnormality in governor, pump controller power source (controller LED is OFF)….2578
E-2 [E308] Abnormality in fuel control dial input value is displayed….2579
E-3 [317] Abnormality (disconnection) in motor drive system is displayed….2580
E-4 [318] Abnormality (short circuit) in motor drive system is displayed….2581
E-5 [E306] Abnormality in feedback potentiometer system is displayed….2582
E-6 [E315] Abnormality (short circuit) in battery relay output system is displayed….2583
E-7 [E316] Abnormality (step-out) in motor displayed….2584
E-8 Engine does not start….2585
E-9 Engine speed is irregular….2587
E-10 Lack of output (engine high idling speed is to low)….2591
E-11 Engine does not stop….2593
E-12 Defective operation of battery relay system (engine does not stop)….2595
TROUBLESHOOTING OF ENGINE SYSTEM….2597
METHOD OF USING TROUBLESHOOTING CHARTS….2598
S-1 Starting performance is poor (starting always takes time)….2602
S-2 Engine does not start….2603
S-3 Engine does not pick up smoothly (follow up is poor)….2606
S-4 Engine stops during operations….2607
S-5 Engine does not rotate smoothly (hunting)….2608
S-6 Engine lacks output (no power)….2609
S-7 Engine smoke is black (incomplete combustion)….2610
S-8 Oil consumption is excessive (or exhaust smoke is blue)….2611
S-9 Oil becomes contaminated quickly….2611
S-10 Fuel consumption is excessive….2611
S-11 Oil is in cooling water, or water spurts back, or water level goes down….2611
S-12 Oil pressure caution lamp lights up (drop in oil pressure)….2611
S-13 Oil level rises (water, fuel in oil)….2612
S-14 Water temperature becomes too high (overheating)….2613
S-15 Abnormal noise is made….2614
S-16 Vibration is excessive….2615
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM (C MODE)….2616
POINT TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM….2617
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE….2618
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS….2624
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE….2626
C-1 Abnormality in controller power source system (controller LED is OFF)….2628
C-2 [E232] Short Circuit in front pump TVC solenoid system is displayed….2629
C-3 [E233] Disconnection in front pump TVC solenoid system is displayed….2631
C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed….2633
C-5 [E237] Disconnection in rear pump TVC solenoid system is displayed….2635
C-6 [E202] Short circuit in LS select solenoid system is displayed….2637
C-7 [E212] Disconnection in LS select solenoid system is displayed….2638
C-8 [E203[ Short circuit in swing brake solenoid system is displayed….2639
C-9 [E213] Disconnection in swing brake solenoid system is displayed….2641
C-10 [E204] Short circuit in pump merge/divider solenoid system is displayed….2643
C-11 [E214] Disconnection in pump merge/divider solenoid system is displayed….2644
C-12 [E206] Short circuit in travel speed solenoid system is displayed….2645
C-13 [E216] Disconnection in travel speed selector solenoid system is displayed….2646
C-14 [E217] Model selection input error is displayed….2647
C-15 [E222] Short circuit in LS-EPC solenoid system is displayed….2649
C-16 [E223] Disconnection in LS-EPC solenoid system is displayed….2650
C-17 [E224] Abnormality in front pump pressure sensor system is displayed….2651
C-18 [E225] Abnormality in rear pump pressure sensor system is displayed….2652
C-19 [E226] Abnormality in pressure sensor power source system is displayed….2653
C-20 [E227] Abnormality in engine speed sensor system is displayed….2654
C-21 Abnormality in machine push up solenoid system (no service code is displayed….2655
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)….2657
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE….2658
F-1 Bit pattern 20-(1) Swing oil pressure switch does not light up….2660
F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up….2661
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up….2662
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up….2663
F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up….2664
F-6 Bit pattern 20-(6) Arm OUT oil pressure switch, does not light up….2665
F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up….2666
F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up….2667
F-9 Bit pattern 21-(3) Swing lock switch does not light up….2668
F-11 Bit pattern 22-(6) L.H. knob switch does not light up….2669
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)….2670
PUMP MERGE/DIVIDER LOGIC….2671
LS SELECT LOGIC….2672
SOLENOID ACTUATION TABLE….2672
TABLE OF FAILURE MODES AND CAUSES….2673
H-1 Speeds of all work equipment, swing, travel are slow or lack power….2677
H-2 There is excessive drop in engine speed, or engine stalls….2679
H-3 No work equipment, travel, swing move….2680
H-4 Abnormal noise generated (around pump)….2680
H-5 Auto-deceleration does not work (when PPC shuttle valve is cause)….2681
H-6 Fine control ability is poor or response is poor….2682
H-7 Boom is slow or lacks power….2683
H-8 Arm is slow or lacks power….2685
H-9 Bucket is slow or lacks power….2687
H-10 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)….2688
H-11 Excessive hydraulic drift (boom, arm, bucket)….2688
H-12 Excessive time lag (engine at low idling)….2689
H-13 Other equipment moves when single circuit is relieved….2689
H-14 In L/O, F/O modes, work equipment speed is faster than specified speed….2690
H-15 Defective actuation of machine push-up function….2690
H-16 In compound operations, work equipment with larger load is slow….2690
H-17 In swing + boom RAISE, boom RAISE is slow….2691
H-18 In swing + arm, arm is slow….2691
H-19 In swing + travel, travel speed drops excessively….2691
H-20 Travel deviation….2692
H-21 Travel speed is slow….2693
H-22 Steering does not turn easily or lacks power….2695
H-23 Travel speed does not switch or is faster than specified speed….2697
H-24 Travel does not move (one side only)….2697
H-25 Does not swing….2698
H-26 Swing acceleration is poor or swing speed is slow….2699
H-27 Excessive overrun when stopping swing….2701
H-28 Excessive shock when stopping swing (one direction only)….2702
H-29 Excessive abnormal noise when stopping swing….2702
H-30 Excessive hydraulic drift of swing….2703
H-31 Swing speed is faster than specified swing speed….2704
TROUBLESHOOTING OF HYDRAULIC, MONITOR SYSTEM (M MODE)….2705
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE….2706
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE….2708
M-1 [E101] Abnormality in error data is displayed….2711
M-2 [E103] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed….2712
M-3 [E104] Air cleaner clogging detected is displayed….2713
M-5 [E108] Engine water temperature 105°C detected is displayed….2713
M-6 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds ….2714
M-7 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out….2716
M-8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine(mode)….2716
M-9 When starting switch is turned ON (engine stopped), basic check items flashes….2717
M-11 When starting switch is turned ON and engine is started, basic check item flash….2720
M-12 When starting switch is turned ON (engine speed), caution items, emergency items flash (battery, engine oil pressure lamp n….2722
M-13 When starting switch is turned ON and engine is started, caution items, emergency items flash (when there is no abnormality….2724
M-14 When staring switch is turned ON (engine stopped), buzzer does not sound for 1 second Caution item flashes but does not sou….2727
M-15 No abnormality is displayed on monitor but buzzer sounds….2727
M-16 Night light on monitor panel does not light up (liquid crystal display is normal)….2728
M-17 Coolant temperature gauge does not rise….2729
M-18 Coolant temperature gauge does not give any display (none of gauge lamps light up during operation)….2729
M-19 Fuel level gauge always displays FULL….2730
M-20 Fuel level gauge does not give display….2730
M-21 Swing lock switch is turned ON (LOCK) but 4 swing lock monitor) does not light up….2731
M-22 Swing prolix switch is turned ON (prolix) but 8 (swing lock monitor) does not flash….2731
M-23 Service meter does not advance while engine is running….2732
M-24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed….2732
M-25 Defective fuel level sensor system….2733
M-26 Defective coolant temperature sensor system….2734
M-27 Defective engine oil level sensor system….2735
M-28 Defective coolant level sensor system….2736
M-29 Defective hydraulic oil level sensor system….2737
M-30 Wiper does not work or switch is not being used but wiper is actuated….2738
30 DISASSEMBLY AND ASSEMBLY….2742
METHOD OF USING MANUAL….2744
PRECAUTIONS WHEN CARRYING OUT OPERATION….2746
SPECIAL TOOL LIST….2748
SKETCHES OF SPECIAL TOOLS….2754
STARTING MOTOR….2762
ALTERNATOR….2762
ENGINE OIL COOLER….2762
FUEL INJECTION PUMP….2762
WATER PUMP….2763
NOZZLE HOLDER….2763
TURBOCHARGER….2763
THERMOSTAT….2763
ENGINE FRONT SEAL….2764
ENGINE REAR SEAL….2764
CYLINDER HEAD….2764
AFTER COOLER….2764
GOVERNOR MOTOR….2765
REMOVAL….2765
INSTALLATION….2765
HYDRAULIC COOLER….2766
REMOVAL….2766
INSTALLATION….2767
RADIATOR, HYDRAULIC COOLER….2768
REMOVAL….2768
INSTALLATION….2769
ENGINE, MAIN PUMP….2770
REMOVAL….2770
INSTALLATION….2773
DAMPER….2774
REMOVAL….2774
INSTALLATION….2774
FUEL TANK….2775
REMOVAL….2775
INSTALLATION….2775
CENTER SWIVEL JOINT….2776
REMOVAL….2776
INSTALLATION….2776
DISASSEMBLY….2777
ASSEMBLY….2777
FINAL DRIVE….2778
REMOVAL….2778
INSTALLATION….2778
DISASSEMBLY….2779
ASSEMBLY….2783
TRAVEL MOTOR….2790
DISASSEMBLY….2790
ASSEMBLY….2794
SPROCKET….2805
REMOVAL….2805
INSTALLATION….2805
SWING MOTOR….2806
REMOVAL….2806
INSTALLATION….2806
DISASSEMBLY….2807
ASSEMBLY….2810
SWING MACHINERY….2817
REMOVAL….2817
INSTALLATION….2817
DISASSEMBLY….2818
ASSEMBLY….2822
REVOLVING FRAME….2827
REMOVAL….2827
INSTALLATION….2828
SWING CIRCLE….2829
REMOVAL….2829
INSTALLATION….2829
IDLER, RECOIL SPRING….2830
REMOVAL….2830
INSTALLATION….2830
IDLER….2831
DISASSEMBLY….2831
ASSEMBLY….2832
RECOIL SPRING….2834
DISASSEMBLY….2834
ASSEMBLY….2835
TRACK ROLLER….2836
REMOVAL….2836
INSTALLATION….2836
DISASSEMBLY….2837
ASSEMBLY….2838
CARRIER ROLLER….2840
REMOVAL….2840
INSTALLATION….2840
DISASSEMBLY….2841
ASSEMBLY….2842
TRACK SHOE….2845
REMOVAL….2845
INSTALLATION….2845
HYDRAULIC TANK….2846
REMOVAL….2846
INSTALLATION….2847
CONTROL PUMP….2848
REMOVAL….2848
INSTALLATION….2848
MAIN PUMP….2849
REMOVAL….2849
INSTALLATION….2850
DISASSEMBLY….2851
ASSEMBLY….2857
CHECKING CONTACT….2867
MAIN PUMP INPUT SHAFT OIL SEAL….2869
REMOVAL….2869
INSTALLATION….2869
CONTROL VALVE….2870
REMOVAL….2870
INSTALLATION….2872
DISASSEMBLY….2873
ASSEMBLY….2876
PUMP MERGE/DIVIDER VALVE….2880
DISASSEMBLY….2880
ASSEMBLY….2880
PRESSURE COMPENSATION VALVE….2881
DISASSEMBLY….2881
ASSEMBLY….2881
SERVO VALVE FOR FRONT PUMP….2882
REMOVAL….2882
INSTALLATION….2882
SERVO VALVE FOR REAR PUMP….2883
REMOVAL….2883
INSTALLATION….2883
LS-EPC SOLENOID VALVE….2884
REMOVAL….2884
INSTALLATION….2884
SOLENOID VALVE….2885
REMOVAL….2885
INSTALLATION….2885
WORK EQUIPMENT PPC VALVE….2886
REMOVAL….2886
INSTALLATION….2886
DISASSEMBLY….2887
ASSEMBLY….2887
TRAVEL PPC VALVE….2888
REMOVAL….2888
INSTALLATION….2888
DISASSEMBLY….2889
ASSEMBLY….2890
PPC SHUTTLE VALVE….2891
REMOVAL….2891
INSTALLATION….2892
DISASSEMBLY….2893
ASSEMBLY….2894
BOOM LOCK VALVE….2895
REMOVAL….2895
INSTALLATION….2895
DISASSEMBLY….2895
ASSEMBLY….2895
BOOM CYLINDER….2896
REMOVAL….2896
INSTALLATION….2897
ARM CYLINDER….2898
REMOVAL….2898
INSTALLATION….2899
BUCKET CYLINDER….2900
REMOVAL….2900
INSTALLATION….2901
HYDRAULIC CYLINDER….2902
DISASSEMBLY….2902
ASSEMBLY….2904
WORK EQUIPMENT….2906
REMOVAL….2906
INSTALLATION….2907
BUCKET….2908
REMOVAL….2908
INSTALLATION….2909
ARM….2910
REMOVAL….2910
INSTALLATION….2911
BUCKET, ARM….2912
REMOVAL….2912
INSTALLATION….2913
BOOM….2914
REMOVAL….2914
INSTALLATION….2915
OPERATORS CAB….2916
REMOVAL….2916
INSTALLATION….2917
COUNTERWEIGHT….2918
REMOVAL….2918
INSTALLATION ….2918
COUNTERWEIGHT WITH COUNTERWEIGHT REMOVER….2919
REMOVAL….2919
INSTALLATION….2922
AIR CONDITIONER COMPRESSOR….2923
REMOVAL….2923
INSTALLATION….2923
CONDENSER….2924
REMOVAL….2924
INSTALLATION….2924
AIR CONDITIONER….2925
REMOVAL….2925
INSTALLATION….2926
GOVERNOR, PUMP CONTROLLER….2927
REMOVAL….2927
INSTALLATION….2927
MONITOR PANEL….2928
REMOVAL….2928
INSTALLATION….2928
CONTROL STAND CASE….2929
REMOVAL….2929
INSTALLATION….2930
40 MAINTENANCE STANDARD….2931
ENGINE MOUNT….2932
RADIATOR AND OIL COOLER….2933
SWING MACHINERY….2934
FINAL DRIVE….2936
SWING CIRCLE….2938
TRACK FRAME AND RECOIL SPRING – PC400LC-6….2939
TRACK FRAME AND RECOIL SPRING – PC400HD-6….2940
CARRIER ROLLER….2942
IDLER….2943
TRACK….2945
TRACK ROLLER….2947
HYDRAULIC PUMP….2948
CONTROL PUMP AND RELIEF VALVE….2949
CONTROL VALVE….2950
SUCTION SAFETY VALVE….2956
SWING MOTOR….2957
TRAVEL MOTOR….2958
WORK EQUIPMENT, SWING PPC VALVE….2959
TRAVEL PPC VALVE….2960
SERVICE PPC VALVE….2961
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE….2962
EPC SOLENOID VALVE….2963
CENTER SWIVEL JOINT….2964
BOOM HOLDING VALVE….2965
HYDRAULIC CYLINDER….2966
WORK EQUIPMENT….2968
DIMENSIONS OF WORK EQUIPMENT….2970
SEAM02080305 – Hydraulic Excavator PC400-3, PC400LC-3 Operation & Maintenance Manual….2973
SEAM02080502 – Hydraulic Excavator PC400-5, PC400LC-5 Operation & Maintenance Manual….3163
CONTENTS….3167
OPERATION….3167
GENERAL LOCATIONS AND SPECIFICATIONS….3168
INSTRUMENTS AND CONTROLS….3170
METHOD OF USING MODE SELECTOR SWITCHES….3210
CHECK BEFORE STARTING….3214
OPERATING YOUR MACHINE….3220
INVERSION AND REPLACEMENT OF BUCKET….3244
HANDLING THE CLAMSHELL BUCKET….3246
SELECTION OF TRACK SHOES….3248
SELECTION OF BUCKET TEETH….3250
TRANSPORTATION….3251
INSTALLATION OF OPTIONAL ELECTRICAL EQUIPMENT….3258
COLD WEATHER OPERATION….3260
MAINTENANCE….3269
PERIODIC MAINTENANCE….3269
PRECAUTIONS WHEN DISASSEMBLING MACHINE….3270
BLEEDING AIR FROM CIRCUIT….3272
PERIODICAL REPLACEMENT OF SAFETY PARTS….3276
MAINTENANCE TABLE….3280
OIL FILLER AND LEVEL GAUGE POSITIONS….3284
EVERY 100 HOURS SERVICE….3286
EVERY 250 HOURS SERVICE….3292
EVERY 500 HOURS SERVICE….3300
EVERY 1000 HOURS SERVICE….3304
EVERY 2000 HOURS SERVICE….3308
EVERY 4000 HOURS SERVICE….3313
WHEN REQUIRED….3314
ADJUSTMENT….3332
TROUBLE SHOOTING GUIDE….3334
SERVICE METER….3344
MACHINE AND ENGINE SERIAL NUMBERS….3346
FUEL, COOLANT AND LUBRICANTS….3348
LOADING SHOVEL (with bottom dump bucket)….3351
SAFETY AND OPERATION….3371
CONTENTS….3373
SAFETY HINTS….3374
RADIO….3390
LOCKING CAP….3394
OPERATING THE CAR COOLER….3396
OPERATING THE AIR CONDITIONER….3400
EXCAVATOR’S WORK….3410
HANDLING OF BATTERY….3412
PRECAUTIONS FOR MAINTENANCE….3418
STORAGE….3424
COOLANT AND LUBRICANTS….3426
SEBM02080307 – Hydraulic Excavator PC400-3, PC400LC-3 Shop Manual….3430
SEBM0208A03 – Hydraulic Excavator PC400-1, PC400LC-1 Shop Manual….4204
SEBM037602 – Hydraulic Excavator PC400-7, PC400LC-7 Shop Manual….4816
COVER….4816
CONTENTS….4817
01 GENERAL….4844
SPECIFICATION DRAWINGS….4845
SPECIFICATIONS….4847
WEIGHT TABLE….4849
FUEL, COOLANT AND LUBRICANTS….4851
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….4854
ENGINE RELATED PARTS….4855
RADIATOR・OIL COOLER・AFTERCOOLER….4856
POWER TRAIN….4857
FINAL DRIVE….4858
SPROCKET….4860
SWING MACHINERY….4862
SWING CIRCLE….4864
TRACK FRAME AND RECOIL SPRING….4865
IDLER….4867
CARRIER ROLLER….4869
TRACK ROLLER….4870
TRACK SHOE….4871
HYDRAULIC PIPING DRAWING….4875
HYDRAULIC TANK….4877
HYDRAULIC PUMP….4878
LS(PC)-EPC VALVE….4896
VARIABLE VOLUME VALVE….4899
CONTROL VALVE….4901
MAIN RELIEF VALVE….4914
CLSS….4915
SELF PRESSURE REDUCING VALVE….4918
SWING MOTOR….4921
REVERSAL PREVENTION VALVE….4926
CENTER SWIVEL JOINT….4928
TRAVEL MOTOR….4929
TRAVEL JUNCTION VALVE….4940
VALVE CONTROL….4942
TRAVEL PPC SHUTTLE VALVE….4943
WORK EQUIPMENT・SWING PPC VALVE….4947
TRAVEL PPC VALVE….4951
SERVICE PPC VALVE….4958
SOLENOID VALVE….4959
PPC ACCUMULATOR….4961
RETURN OIL FILTER….4962
BOOM HYDRAULIC DRIFT PREVENTION VALVE….4963
ARM HYDRAULIC DRIFT PREVENTION VALVE….4968
QUICK RETURN VALVE….4972
LIFT CHECK VALVE….4974
ATTACHMENT CIRCUIT SELECTOR VALVE….4975
HOLDING VALVE….4977
HYDRAULIC CYLINDER….4982
WORK EQUIPMENT….4984
COMBUSTION HEATER AND PARTS RELATED TO HEATER….4990
ENGINE CONTROL….4992
ELECTRONIC CONTROL SYSTEM….4997
MONITOR SYSTEM (MULTI MONITOR SPECIFICATION)….5024
7-SEGMENT MONITOR SYSTEM….5044
SENSOR….5051
20 TESTING AND ADJUSTING….5054
STANDARD VALUE TABLE FOR ENGINE….5055
STANDARD VALUE TABLE FOR CHASSIS….5056
TESTING AND ADJUSTING….5065
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE….5066
MEASURING ENGINE SPEED….5068
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)….5069
MEASURING EXHAUST TEMPERATURE….5070
MEASURING EXHAUST GAS COLOR….5071
ADJUSTING VALVE CLEARANCE….5072
MEASURING COMPRESSION PRESSURE….5074
MEASURING BLOW-BY PRESSURE….5076
MEASURING ENGINE OIL PRESSURE….5077
HANDLING OF FUEL SYSTEM DEVICES….5078
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM….5078
MEASURING FUEL PRESSURE….5079
BLEEDING AIR FROM FUEL CIRCUIT….5080
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE….5082
ADJUSTING ENGINE SPEED SENSOR….5083
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION….5084
MEASURING CLEARANCE OF SWING CIRCLE BEARING….5085
TESTING AND ADJUSTING TRACK SHOE TENSION….5086
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS….5087
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT….5091
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT….5092
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT….5095
MEASURING SOLENOID VALVE OUTPUT PRESSURE….5099
MEASURING PPC VALVE OUTPUT PRESSURE….5102
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES….5104
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT….5105
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT….5106
MEASURING OIL LEAKAGE….5107
BLEEDING AIR FROM EACH PART….5109
TESTING PROCEDURE OF DIODE….5112
SPECIAL FUNCTIONS OF MONITOR PANEL (MULTI MONITOR SPECIFICATION)….5113
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER….5140
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM (STANDARD SPECIFICATION)….5141
PM-CLINIC SERVICE….5143
TROUBLESHOOTING….5150
POINTS TO REMEMBER WHEN TROUBLESHOOTING….5151
SEQUENCE OF EVENTS IN TROUBLESHOOTING….5152
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….5153
CHECKS BEFORE TROUBLESHOOTING….5161
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING….5162
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM….5166
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….5183
T-BRANCH BOX AND T-BRANCH TABLE….5205
TROUBLESHOOTING WHEN ERROR CODE“ELECTRICAL SYSTEM”AND FAILURE CODE“MECHANICAL SYSTEM”ARE DISPLAYED….5208
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….5210
ERROR CODE IN ELECTRICAL SYSTEM [E112] (SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)….5212
ERROR CODE IN ELECTRICAL SYSTEM [E113] (SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)….5214
ERROR CODE IN ELECTRICAL SYSTEM [E114] (SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM)….5216
ERROR CODE IN ELECTRICAL SYSTEM [E115] (ABNORMAL WINDSHIELD WIPER MOTION)….5218
ERROR CODE IN ELECTRICAL SYSTEM [E116] (ABNORMALITY IN RETRACTING WINDSHIELD WIPER)….5220
ERROR CODE IN ELECTRICAL SYSTEM [E117] (ENG. CONTROLLER S-NET COMM. ERR.)….5222
ERROR CODE IN ELECTRICAL SYSTEM [E118] (PUMP CONTROLLER S-NET COMM. ERR.)….5224
ERROR CODE IN ELECTRICAL SYSTEM [E128] (MONITOR COMM. ABNORMALITY)….5226
ERROR CODE IN ELECTRICAL SYSTEM [E201] (SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)….5228
ERROR CODE IN ELECTRICAL SYSTEM [E203] (SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)….5229
ERROR CODE IN ELECTRICAL SYSTEM [E204] (SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)….5231
ERROR CODE IN ELECTRICAL SYSTEM [E205] (SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)….5232
ERROR CODE IN ELECTRICAL SYSTEM [E206] (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID)….5233
ERROR CODE IN ELECTRICAL SYSTEM [E211] (DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)….5234
ERROR CODE IN ELECTRICAL SYSTEM [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)….5235
ERROR CODE IN ELECTRICAL SYSTEM [E214] (DISCONNECTION IN MERGE/DIVIDE SOLENOID)….5237
ERROR CODE IN ELECTRICAL SYSTEM [E215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID)….5238
ERROR CODE IN ELECTRICAL SYSTEM [E216] (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)….5239
ERROR CODE IN ELECTRICAL SYSTEM [E217] (ABNORMAL INPUT MODEL CODE)….5240
ERROR CODE IN ELECTRICAL SYSTEM [E218] (S-NET COMM. DISC.)….5242
ERROR CODE IN ELECTRICAL SYSTEM [E222] (SHORT-CIRCUITING IN LS-EPC SOLENOID)….5244
ERROR CODE IN ELECTRICAL SYSTEM [E223] (DISCONNECTION IN LS-EPC SOLENOID SYSTEM)….5245
ERROR CODE IN ELECTRICAL SYSTEM [E224] (F PUMP P. SENSOR ABNORMALITY)….5246
ERROR CODE IN ELECTRICAL SYSTEM [E225] (R PUMP P. SENSOR ABNORMALITY)….5248
ERROR CODE IN ELECTRICAL SYSTEM [E226] (PRESS. SENSOR POWER ABNORMALITY)….5250
ERROR CODE IN ELECTRICAL SYSTEM [E227] (ABNORMALITY IN ENGINE ROTATION SENSOR)….5252
ERROR CODE IN ELECTRICAL SYSTEM [E228] (SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)….5253
ERROR CODE IN ELECTRICAL SYSTEM [E232] (SHORT-CIRCUITING IN PC-EPC SOLENOID)….5254
ERROR CODE IN ELECTRICAL SYSTEM [E233] (DISCONNECTION IN PC-EPC SOLENOID SYSTEM)….5256
ERROR CODE IN ELECTRICAL SYSTEM [E238] (DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY)….5258
ERROR CODE IN ELECTRICAL SYSTEM [E245] (SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)….5260
ERROR CODE IN ELECTRICAL SYSTEM [E246] (DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)….5261
ERROR CODE IN ELECTRICAL SYSTEM [E247] (ARM IN PPC PRESSURE SENSOR ABNORMALITY)….5262
ERROR CODE IN ELECTRICAL SYSTEM [E248] (BUCKET CURL PPC PRESSURE SENSOR ABNORMALITY)….5264
ERROR CODE IN ELECTRICAL SYSTEM [E257] (PUMP ABNORMALITY)….5266
ERROR CODE IN ELECTRICAL SYSTEM [E315] (BATTERY RELAY DRIVE S/C)….5268
ERROR CODE IN ELECTRICAL SYSTEM [E91B] (ENGINE NE SENSOR PROBLEM)….5270
ERROR CODE IN ELECTRICAL SYSTEM [E91C] (ENGINE G SENSOR PROBLEM)….5271
ERROR CODE IN ELECTRICAL SYSTEM [E920] (ENGINE TYPE SELECTION ERROR)….5272
ERROR CODE IN ELECTRICAL SYSTEM [E921] (ENGINE TYPE MISMATCH)….5274
ERROR CODE IN ELECTRICAL SYSTEM [E931] (FUEL DIAL SYS. ERROR)….5275
ERROR CODE IN ELECTRICAL SYSTEM [E934] (ENGINE COOLANT SENSOR HI ERROR)….5277
ERROR CODE IN ELECTRICAL SYSTEM [E936] (ENGINE OIL PRESS. SW. ERROR)….5279
ERROR CODE IN ELECTRICAL SYSTEM [E93C] (ENGINE BOOST SENSOR ERROR)….5281
ERROR CODE IN ELECTRICAL SYSTEM [E93D] (ENGINE FUEL TEMP. SENSOR ERROR)….5283
ERROR CODE IN ELECTRICAL SYSTEM [E953] (ENGINE COMM. ABNORMALITY)….5285
ERROR CODE IN ELECTRICAL SYSTEM [E954] (SHORT ENGINE STARTER SW.)….5287
ERROR CODE IN ELECTRICAL SYSTEM [E955] (ENGINE S-NET ERROR)….5289
ERROR CODE IN ELECTRICAL SYSTEM [E956] (ENGINE POWER FAILURE (1))….5291
ERROR CODE IN ELECTRICAL SYSTEM [E957] (ENGINE POWER FAILURE (2))….5293
ERROR CODE IN ELECTRICAL SYSTEM [E95A] (ENGINE Q-ADJ. SW. SIGNAL ERROR)….5295
ERROR CODE IN ELECTRICAL SYSTEM [E96A] (ENGINE COOLANT SENSOR LO ERROR)….5296
ERROR CODE IN ELECTRICAL SYSTEM [E970] (PCV1 OVER CURRENT)….5298
ERROR CODE IN ELECTRICAL SYSTEM [E971] (PCV2 OVER CURRENT)….5299
ERROR CODE IN ELECTRICAL SYSTEM [E974] (PCV1 LINE CUT)….5300
ERROR CODE IN ELECTRICAL SYSTEM [E975] (PCV2 LINE CUT)….5301
ERROR CODE IN ELECTRICAL SYSTEM [E977] (RAIL PRESS. SENSOR ERROR)….5302
ERROR CODE IN ELECTRICAL SYSTEM [E979] (RAIL PRESS. HIGH)….5304
ERROR CODE IN ELECTRICAL SYSTEM [E97A] (RAIL PRESS. ABNORMAL)….5304
ERROR CODE IN ELECTRICAL SYSTEM [E97B] (RAIL PRESS. LOW)….5305
ERROR CODE IN ELECTRICAL SYSTEM [E97C] (RAIL PRESS. TOO LOW)….5307
ERROR CODE IN ELECTRICAL SYSTEM [E97D] (RAIL PRESS. OUT OF CONTROL)….5307
ERROR CODE IN ELECTRICAL SYSTEM [E980] (ENG. CONTROLLER ABNORMALITY)….5308
ERROR CODE IN ELECTRICAL SYSTEM [E981] (FUEL INJECTOR 1 DISC.)….5310
ERROR CODE IN ELECTRICAL SYSTEM [E982] (FUEL INJECTOR 2 DISC.)….5311
ERROR CODE IN ELECTRICAL SYSTEM [E983] (FUEL INJECTOR 3 DISC.)….5312
ERROR CODE IN ELECTRICAL SYSTEM [E984] (FUEL INJECTOR 4 DISC.)….5313
ERROR CODE IN ELECTRICAL SYSTEM [E985] (FUEL INJECTOR 5 DISC.)….5314
ERROR CODE IN ELECTRICAL SYSTEM [E986] (FUEL INJECTOR 6 DISC.)….5315
ERROR CODE IN ELECTRICAL SYSTEM [E98A] (FUEL INJECTOR 1-3 S/C)….5316
ERROR CODE IN ELECTRICAL SYSTEM [E98B] (FUEL INJECTOR 4-6 S/C)….5318
ERROR CODE IN MECHANICAL SYSTEM [A000N1] (ENGINE HIGH-IDLING SPEED OUT OF STANDARD)….5320
ERROR CODE IN MECHANICAL SYSTEM [A000N2] (ENGINE LOW-IDLING SPEED OUT OF STANDARD)….5320
FAILURE CODE IN MECHANICAL SYSTEM [AA10NX] (AIRCLEANER CLOGGING)….5321
FAILURE CODE IN MECHANICAL SYSTEM [AB00KE] (CHARGE VOLTAGE LOW)….5323
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG] (ENG. OIL PRESS. LOW)….5325
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK] (ENG. OIL LEVEL LOW)….5327
FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS] (ENG. WATER OVERHEAT)….5328
FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK] (ENG. WATER LVL LOW)….5329
FAILURE CODE IN MECHANICAL SYSTEM [B@HANS] (HYDR. OIL OVERHEAT)….5330
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….5331
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….5333
E-1 ENGINE DOES NOT START (THE ENGINE DOES NOT ROTATE)….5334
E-2 PREHEATER DOES NOT OPERATE….5337
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK….5339
E-4 AUTO-DECELERATOR DOES NOT OPERATE….5340
E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE….5341
E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE….5343
E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY….5344
E-8 ATTACHMENT CIRCUIT DOES NOT CHANGE….5346
E-9 NO DISPLAY IN MONITOR PANEL AT ALL….5348
E-10 PART OF DISPLAY ON MONITOR PANEL IS MISSING….5349
E-11 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL….5349
E-12 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING….5350
E-13 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY….5351
E-14 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY….5353
E-15 FUEL GAUGE DOES NOT DISPLAY CORRECTLY….5354
E-16 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY….5355
E-17 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED….5357
E-18 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK….5359
E-19 ALARM BUZZER CANNOT BE CANCELLED….5363
E-20 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….5364
E-21 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….5365
E-22 "ARM IN" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION….5366
E-23 "ARM DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….5367
E-24 "BUCKET CURL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION….5368
E-25 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….5369
E-26 "SWING" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION….5370
E-27 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….5372
E-28 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….5374
E-29 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….5376
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING….5378
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)….5380
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM….5381
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….5383
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE LOW….5384
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS….5385
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE….5386
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP….5386
H-5 AUTO-DECELERATOR DOES NOT WORK….5387
H-6 FINE CONTROL MODE DOES NOT FUNCTION….5387
H-7 BOOM MOVES SLOWLY OR LACKS POWER….5388
H-8 ARM MOVES SLOWLY OR LACKS POWER….5389
H-9 BUCKET MOVES SLOWLY OR LACKS POWER….5390
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION….5390
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT….5391
H-12 WORK EQUIPMENT HAS BIG TIME LAG….5392
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT….5392
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK….5392
H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK….5393
H-16 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY….5394
H-17 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY….5394
H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY….5394
H-19 MACHINE SWERVES IN TRAVEL….5395
H-20 MACHINE TRAVELS SLOWLY….5396
H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER….5397
H-22 TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED….5398
H-23 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)….5399
H-24 MACHINE DOES NOT SWING….5400
H-25 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW….5401
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING….5402
H-27 THERE IS BIG SHOCK WHEN STOPPING SWING….5403
H-28 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING….5403
H-29 SWING NATURAL DRIFT IS TOO BIG….5404
H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE….5405
H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED….5405
TROUBLESHOOTING OF ENGINE (S MODE)….5406
POINTS TO REMEMBER WHEN TROUBLESHOOTING….5407
METHOD OF USING TROUBLESHOOTING CHARTS….5408
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)….5411
S-2 ENGINE DOES NOT START….5412
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)….5415
S-4 ENGINE STOPS DURING OPERATIONS….5416
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)….5417
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)….5418
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)….5419
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)….5420
S-9 OIL BECOMES CONTAMINATED QUICKLY….5421
S-10 FUEL CONSUMPTION IS EXCESSIVE….5422
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)….5423
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)….5424
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)….5425
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)….5426
S-15 ABNORMAL NOISE IS MADE….5427
S-16 VIBRATION IS EXCESSIVE….5428
30 DISASSEMBLY AND ASSEMBLY….5429
HOW TO READ THIS MANUAL….5430
PRECAUTIONS WHEN PERFORMING OPERATION….5432
SPECIAL TOOL LIST….5434
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY….5441
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL….5448
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL….5452
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY….5455
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY….5458
REMOVAL AND INSTALLATION OF NOZZLE TIP….5461
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY….5463
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY….5464
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY….5466
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY….5468
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY….5473
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY….5474
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY….5475
REMOVAL AND INSTALLATION OF SPROCKET….5482
REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY….5483
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY….5484
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY….5491
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY….5493
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY….5494
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY….5497
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY….5499
REMOVAL AND INSTALLATION OF OPERATOR’S CAB (STANDARD SPECIFICATION)….5501
REMOVAL AND INSTALLATION OF PUMP CONTROLLER (STANDARD SPECIFICATION)….5504
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY….5505
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY….5508
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY….5509
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY….5511
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT….5514
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY….5515
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY….5518
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY….5522
DISASSEMBLY AND ASSEMBLY OF OF CENTER SWIVEL JOINT ASSEMBLY….5524
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VELVE ASSEMBLY….5525
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY….5526
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY….5527
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY….5532
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)….5535
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY….5545
70 SUPPLEMENT FOR OFF-SET BOOM EXCAVATOR….5551
SPECIFICATION DRAWINGS….5552
SPECIFICATIONS….5553
WEIGHT TABLE….5554
TESTING AND ADJUSTING….5556
TROUBLESHOOTING….5557
MAINTENANCE STANDARD….5559
90 OTHERS….5569
HYDRAULIC CIRCUIT DIAGRAM (1/2)….5570
HYDRAULIC CIRCUIT DIAGRAM (2/2)….5571
ELECTRICAL CIRCUIT DIAGRAM (1/5) (EXTREME COLD SPEC.)….5572
ELECTRICAL CIRCUIT DIAGRAM (2/5) (EXTREME COLD SPEC.)….5573
ELECTRICAL CIRCUIT DIAGRAM (3/5) (EXTREME COLD SPEC.)….5574
ELECTRICAL CIRCUIT DIAGRAM (4/5) (EXTREME COLD SPEC.)….5575
ELECTRICAL CIRCUIT DIAGRAM (5/5) (EXTREME COLD SPEC.)….5576
Komatsu Hydraulic Excavators PC400, PC400LC, PC400HD Series Repair Service Manuals