Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC400LC-7L, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC400LC-7L 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.
CEAM012900 – Hydraulic Excavator GALEO PC400LC-7L Operation & Maintenance Manual.pdf
CEBM012503 – Hydraulic Excavator PC400LC-7L Shop Manual.pdf
Total Pages: 1,147 pages
File Format: PDF
Language: English
CEAM012900 – Hydraulic Excavator GALEO PC400LC-7L Operation & Maintenance Manual….2
COVER….2
INTRODUCTION….8
FOREWORD….9
SAFETY INFORMATION….9
SAFETY LABELS….10
INTRODUCTION….11
INTENDED USE….11
DIRECTIONS OF MACHINE….11
BREAKING-IN THE NEW MACHINE….11
PRODUCT INFORMATION….12
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION….12
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….12
SERVICE METER LOCATION….13
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….13
TABLE OF CONTENTS….14
SAFETY….20
SAFETY LABELS….21
LOCATION OF SAFETY LABELS….21
SAFETY LABELS….22
SAFETY INFORMATION….29
SAFETY RULES….29
IF ABNORMALITIES ARE FOUND….29
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….29
FIRE EXTINGUISHER AND FIRST AID KIT….29
SAFETY EQUIPMENT….30
KEEP MACHINE CLEAN….30
KEEP OPERATOR'S COMPARTMENT CLEAN….30
LEAVING OPERATOR'S SEAT WITH LOCK….30
HANDRAILS AND STEPS….31
MOUNTING AND DISMOUNTING….31
NO PERSONS ON ATTACHMENTS….31
BURN PREVENTION….32
FIRE PREVENTION AND EXPLOSION PREVENTION….32
ACTION IF FIRE OCCURS….33
WINDSHIELD WASHER FLUID….33
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….34
ATTACHMENT INSTALLATION….34
ATTACHMENT COMBINATIONS….34
CAB WINDOW GLASSES….34
UNAUTHORIZED MODIFICATIONS….34
SAFETY AT JOBSITE….35
WORKING ON LOOSE GROUND….35
DISTANCE TO HIGH VOLTAGE CABLES….36
ENSURE GOOD VISIBILITY….36
VENTILATION FOR ENCLOSED AREA….36
SIGNALMAN'S SIGNAL AND SIGNS….37
EMERGENCY EXIT FROM OPERATOR'S CAB….37
ASBESTOS DUST HAZARD PREVENTION….37
SAFETY MACHINE OPERATION….38
STARTING ENGINE….38
CHECKS BEFORE STARTING ENGINE….38
SAFETY RULES FOR STARTING ENGINE….38
STARTING ENGINE IN COLD WEATHER….39
OPERATION….40
CHECKS BEFORE OPERATION….40
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….40
SAFETY RULES FOR TRAVELING….41
TRAVELING ON SLOPES….42
OPERATIONS ON SLOPES….43
PROHIBITED OPERATIONS….43
OPERATIONS ON SNOW….45
PARKING MACHINE….45
TRANSPORTATION….46
LOADING AND UNLOADING….46
SHIPPING THE MACHINE….46
BATTERY….47
BATTERY HAZARD PREVENTION….47
STARTING ENGINE WITH BOOSTER CABLES….48
TOWING….49
SAFETY RULES FOR TOWING….49
LIFTING OBJECTS WITH BUCKET….50
SAFETY RULES FOR LIFTING OBJECTS….50
SAFETY MAINTENANCE INFORMATION….51
WARNING TAG….51
KEEP WORK PLACE CLEAN AND TIDY….51
APPOINT LEADER WHEN WORKING WITH OTHERS….51
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….52
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….52
PROPER TOOLS….53
ACCUMULATOR….53
PERSONNEL….53
ATTACHMENTS….54
WORK UNDER THE MACHINE….54
NOISE….54
WHEN USING HAMMER….54
WELDING WORKS….55
REMOVING BATTERY TERMINALS….55
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….55
DO NOT DISASSEMBLE RECOIL SPRINGS….55
SAFETY RULES FOR HIGH-PRESSURE OIL….56
SAFETY HANDLING HIGH-PRESSURE HOSES….56
WASTE MATERIALS….56
AIR CONDITIONER MAINTENANCE….57
COMPRESSED AIR….57
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….57
OPERATION….58
MACHINE VIEW ILLUSTRATIONS….59
OVERALL MACHINE VIEW….59
CONTROLS AND GAUGES….60
DETAILED CONTROLS AND GAUGES….62
MONITORING SYSTEM….62
BASIC OPERATION OF MACHINE MONITOR….63
BASIC CHECK MONITORS….65
CAUTION MONITORS….67
EMERGENCY MONITORS….69
METER DISPLAY PORTION….71
GAUGES AND METER….74
MONITOR SWITCHES PORTION….76
SWITCHES….87
CONTROL LEVERS AND PEDALS….92
SUN ROOF….95
WINDSHIELD….95
EMERGENCY EXIT FROM OPERATOR'S CAB….100
DOOR LOCK….100
CAP WITH LOCK….101
HOT AND COOL BOX….102
MAGAZINE BOX….103
ASHTRAY….103
AIR CONDITIONER CONTROLS….104
AIR CONDITIONER CONTROL PANEL….104
METHOD OF OPERATION….109
OTHER FUNCTIONS….116
RADIO….118
CONTROL PANEL….118
CONTROLS OF RADIO….120
PRESET STATION BUTTONS….120
SETTING CORRECT TIME….121
AUXILIARY ELECTRIC POWER….122
24V POWER SOURCE….122
12V POWER SOURCE….122
FUSE….123
FUSIBLELINK….124
CONTROLLERS….125
TOOL BOX….126
GREASE GUN HOLDER….126
ACCUMULATOR….127
RELEASING HYDRAULIC PRESSURE WITH ACCUMULATOR….127
MACHINE OPERATIONS AND CONTROLS….128
BEFORE STARTING ENGINE….128
WALK-AROUND CHECKS….128
CHECKS BEFORE STARTING….129
SEAT ADJUSTMENT….135
SEAT BELT….138
OPERATIONS BEFORE STARTING ENGINE….139
STARTING ENGINE….142
NORMAL STARTING….142
STARTING ENGINE IN COLD WEATHER….144
AFTER STARTING ENGINE….147
WARMING-UP OPERATION….147
COLD WEATHER AREAS….151
STOPPING THE ENGINE….156
MACHINE OPERATION….157
STEERING THE MACHINE….161
STRAIGHT TRAVEL SYSTEM (STS) / ATTACHMENT CONTROL PEDAL….163
LOCKED PIN POSITIONS….163
STRAIGHT TRAVEL DIRECTION….163
SWINGING….164
WORK EQUIPMENT CONTROLS AND OPERATIONS….165
WORKING MODE….167
PROHIBITED OPERATIONS….168
GENERAL OPERATION INFORMATION….170
TRAVELING ON SLOPES….171
ESCAPE FROM MUD….173
RECOMMENDED APPLICATIONS….174
BUCKET REPLACEMENT AND INVERSION….176
PARKING MACHINE….179
CHECK AFTER SHUT OFF ENGINE….180
MACHINE INSPECTION AFTER DAILY WORK….180
LOCKING….181
TRANSPORTATION….182
PRECAUTIONS FOR TRANSPORTATION….182
LIFTING MACHINE….182
PRECAUTIONS WHEN LOADING….183
TRANSPORTATION POSTURE….183
TRACK FRAME GAUGE….187
REDUCING TRACK GAUGE….187
INCREASING TRACK GUAGE….187
COLD WEATHER OPERATION….188
COLD WEATHER OPERATION INFORMATION….188
AFTER DAILY WORK COMPLETION….190
AFTER COLD WEATHER SEASON….190
LONG TERM STORAGE….191
BEFORE STORAGE….191
DURING STORAGE….191
AFTER STORAGE….192
STARTING MACHINE AFTER LONG-TERM STORAGE….192
TROUBLES AND ACTIONS….193
RUNNING OUT OF FUEL….193
PHENOMENA THAT ARE NOT FAILURES….194
TOWING THE MACHINE….195
LIGHTWEIGHT TOWING HOLE….196
SEVERE JOB CONDITION….196
DISCHARGED BATTERY….197
OTHER TROUBLE….201
MAINTENANCE….206
MAINTENANCE INFORMATION….207
LUBRICANTS, COOLANT AND FILTERS….209
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….209
ELECTRIC SYSTEM MAINTENANCE….212
WEAR PARTS….213
WEAR PARTS LIST….213
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….214
TIGHTENING TORQUE SPECIFICATIONS….218
TIGHTENING TORQUE LIST….218
SAFETY CRITICAL PARTS….220
SAFETY CRITICAL PARTS LIST….220
MAINTENANCE SCHEDULE….221
MAINTENANCE SCHEDULE CHART….221
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….223
REPLACE HYDRAULIC OIL FILTER ELEMENT….223
CHANGE OIL IN HYDRAULIC TANK….223
REPLACE ADDITIONAL FILTER ELEMENT FOR BREAKER….223
MAINTENANCE PROCEDURE….224
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….224
REPLACE FUEL FILTER CARTRIDGE….264
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)….224
CHECK ENGINE VALVE CLEARANCE, ADJUST….283
WHEN REQUIRED….225
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….225
CLEAN INSIDE OF COOLING SYSTEM….230
CHECK AND TIGHTEN TRACK SHOE BOLTS….233
CHECK AND ADJUST TRACK TENSION….234
CHECK ELECTRICAL INTAKE AIR HEATER….235
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….236
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….239
REPLACE BUCKET SIDE CUTTER, SHROUD….240
ADJUST BUCKET CLEARANCE….241
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….242
CHECK AND ADJUST AIR CONDITIONER….243
WASH WASHABLE FLOOR….244
BLEEDING AIR FROM HYDRAULIC SYSTEM….248
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT….250
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)….251
CHECK BEFORE STARTING….252
EVERY 250 HOURS MAINTENANCE….253
LUBRICATING….253
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL….254
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….255
CHECK LEVEL OF BATTERY ELECTROLYTE….256
LUBRICATE SWING CIRCLE….259
CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST….259
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….261
EVERY 500 HOURS MAINTENANCE….262
LUBRICATING….262
REPLACE FUEL FILTER CARTRIDGE….264
CHECK, WASH FUEL STRAINER….266
CHECK SWING PINION GREASE LEVEL, ADD GREASE….267
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….268
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDI TIONER)….270
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….271
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….272
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE….273
EVERY 1000 HOURS MAINTENANCE….275
REPLACE HYDRAULIC OIL FILTER ELEMENT….275
CHANGE OIL IN SWING MACHINERY CASE….277
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL….278
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER….278
CHECK PLAY TURBOCHARGER ROTOR….278
REPLACE CORROSION RESISTOR CARTRIDGE….279
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT….280
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)….280
EVERY 2000 HOURS MAINTENANCE….281
CHANGE OIL IN FINAL DRIVE CASE….281
CHECK INJECTOR….281
CLEAN HYDRAULIC TANK STRAINER….282
CLEAN ENGINE BREATHER….282
CLEAN, CHECK TURBOCHARGER….283
CHECK ALTERNATOR, STARTING MOTOR….283
CHECK ENGINE VALVE CLEARANCE, ADJUST….283
CHECK VIBRATION DAMPER….283
EVERY 4000 HOURS MAINTENENCE….284
CHECK WATER PUMP….284
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER….284
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….285
REPLACE INJECTOR NOZZLE ASSEMBLY….285
EVERY 5000 HOURS MAINTENANCE….286
CHANGE OIL IN HYDRAULIC TANK….286
EVERY 8000 HOURS MAINTENANCE….288
REPLACE HIGH-PRESSURE PIPING CLAMP….288
REPLACE FUEL SPRAY PREVENTION CAP….288
SPECIFICATIONS….290
SPECIFICATIONS….291
OPTIONS, ATTACHMENTS….296
GENERAL PRECAUTIONS FOR SAFETY….297
PRECAUTIONS WHEN SELECTING….297
READ THE INSTRUCTION MANUAL THOROUGHLY….297
PRECAUTIONS WHEN REMOVING OR INSTALLING….297
PRECAUTIONS WHEN USING….298
MACHINE READY FOR ATTACHMENT….299
LOCATIONS….299
HYDRAULIC CIRCUIT….303
ATTACHMENT REMOVAL AND INSTALLATION….307
ATTACHMENT OPERATIONS….309
LONG TERM STORAGE….311
SPECIFICATIONS….311
ATTACHMENT GUIDE….312
ATTACHMENT COMBINATIONS….312
RECOMMENDED ATTACHMENT OPERATIONS….314
HYDRAULIC BREAKER….314
CEBM012503 – Hydraulic Excavator PC400LC-7L Shop Manual….322
COVER….322
CONTENTS….323
FOREWORD….334
SAFETY….334
SAFETY NOTICE….334
IMPORTANT SAFETY NOTICE….334
GENERAL PRECAUTIONS….334
PREPARATIONS FOR WORK….334
PRECAUTIONS DURING WORK….335
GENERAL….336
HOW TO READ THE SHOP MANUAL….337
VOLUMES….337
DISTRIBUTION AND UPDATING….337
FILING METHOD….337
REVISED EDITION MARK….337
REVISIONS….337
SYMBOLS….337
HOISTING INSTRUCTIONS….338
HOISTING….338
WIRE ROPES….338
COATING MATERIALS….339
STANDARD TIGHTENING TORQUE….341
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS….341
TIGHTENING TORQUE OF HOSE NUTS….342
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS….342
TIGHTENING TORQUE FOR FLARED NUTS….342
ELECTRIC WIRE CODE….343
CLASSIFICATION BY THICKNESS….343
CLASSIFICATION BY COLOR AND CODE….343
CONVERSION TABLES….344
METHOD OF USING THE CONVERSION TABLE….344
01 GENERAL….350
SPECIFICATIONS….351
WEIGHT TABLE….356
FUEL COOLANT AND LUBRICANTS….358
10 STRUCTURE AND FUNCTION….360
RADIATOR . OIL COOLER . AFTERCOOLER….362
POWER TRAIN….363
FINAL DRIVE….364
SWING MACHINERY….366
SWING CIRCLE….368
TRACK FRAME AND RECOIL SPRING….369
IDLER….371
CARRIER ROLLER….372
TRACK ROLLER….373
TRACK SHOE….375
TRIPLE GROUSER SHOE….378
HYDRAULIC SYSTEM….379
HYDRAULIC PIPING DRAWING….379
HYDRAULIC TANK….381
HYDRAULIC PUMP….383
LS VALVE….388
PC VALVE….388
LS(PS)-EPC VALVE….400
VARIABLE VOLUME VALVE….403
CONTROL VALVE….405
MAIN RELIEF VALVE….419
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)….421
SELF PRESSURE REDUCING VALVE….424
SWING MOTOR….427
RELIEF VALVE….431
REVERSAL PREVENTION VALVE….433
CENTER SWIVEL JOINT….435
TRAVEL MOTOR….436
PARKING BRAKE….441
TRAVEL JUNCTION VALVE….447
CONTROL VALVE….449
TRAVEL PPC SHUTTLE VALVE….451
WORK EQUIPMENT . SWING PPC VALVE….454
TRAVEL PPC VALVE….459
SERVICE PPC VALVE….467
SOLENOID VALVE….468
PPC ACCUMULATOR….470
RETURN OIL FILTER….471
BOOM HYDRAULIC DRIFT PREVENTION VALVE….473
ARM HYDRAULIC DRIFT PREVENTION VALVE….478
QUICK RETURN VALVE….482
LIFT CHECK VALVE….484
ATTACHMENT CIRCUIT SELECTOR VALVE….485
HOLDING VALVE….487
HYDRAULIC CYLINDER….491
BOOM CYLINDER….491
ARM CYLINDER….491
BUCKET CYLINDER….491
WORK EQUIPMENT….493
DIMENSION ARM….495
DIMENSION OF BUCKET….497
AIR CONDITIONER….499
AIR CONDITIONER PIPING….499
ENGINE CONTROL….500
OPERATION OF SYSTEM….500
STARTING ENGINE….500
ENGINE SPEED CONTROL….500
STOPPING ENGINE….500
COMPONENTS OF SYSTEM….501
FUEL CONTROL DIAL….501
ENGINE CONTROLLER….502
ELECTRONIC CONTROL SYSTEM….505
CONTROL FUNCTIONS….505
TOTAL SYSTEM DIAGRAM….507
ENGINE AND PUMP CONTROL FUNCTION….509
PUMP/VALVE CONTROL FUNCTION….514
ONE-TOUCH POWER MAXIMIZING/MACHINE PUSH-UP FUNCTION….517
AUTO-DECELERATION FUNCTION….519
AUTO-WARM-UP/OVERHEAT PREVENTION FUNCTION….521
SWING CONTROL FUNCTION….523
TRAVEL CONTROL FUNCTION….525
ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION (IF EQUIPMENT)….527
SYSTEM COMPONENT PARTS….528
ENGINE REVOLUTION SENSOR….528
PPC OIL PRESSURE SWITCH….529
PUMP PRESSURE SENSOR….530
PUMP CONTROLLER….531
MONITOR SYSTEM….534
MONITOR CONTROL, DISPLAY PORTION….537
MONITOR PORTION….537
MONITOR ITEMS AND DISPLAY….538
SWITCHES….542
SELECT MODE FUNCTION….545
MAINTENANCE FUNCTION….548
SERVICE METER CHECK FUNCTION….551
DISPLAY LCD CHECK FUNCTION….551
SENSOR….553
ENGINE OIL LEVER SENSOR….553
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)….553
COOLANT TEMPERATURE SENSOR….554
HYDRAULIC OIL TEMPERATURE SENSOR….554
FUEL LEVEL SENSOR….554
AIR CLEANER CLOGGING SENSOR….555
20 TESTING, ADJUSTING AND TROUBLESHOOTING….556
STANDARD VALUE TABLE FOR ENGINE….557
STANDARD VALUE TABLE FOR CHASSIS….558
TESTING AND ADJUSTING….568
SERVICE TOOLS….569
MEASURING ENGINE SPEED….571
ENGINE….572
FUEL….572
BLEEDING AIR FROM FUEL CIRCUIT….572
FUEL PRESSURE….572
HANDLING FUEL SYSTEM DEVICES….572
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE….572
RELEASING RESIDUAL FUEL SYSTEM PRESSURE….572
ADJUSTING ENGINE SPEED SENSOR….572
ADJUSTING VALVE CLEARANCE….572
BLOW-BY PRESSURE….572
COMPRESSION PRESSURE….572
ENGINE OIL PRESSURE….572
ENGINE SPEED SENSOR….572
EXHAUST GAS COLOR….572
EXHAUST TEMPERATURE….572
INTAKE AIR PRESSURE (BOOST PRESSURE)….572
FAN BELT AND ALTERNATOR BELT TENSION….573
AIR CONDITIONER COMPRESSOR BELT TENSION….574
SWING CIRCLE BEARING CLEARANCE….575
TRACK SHOE TENSION….576
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS….577
CONTROL CIRCUIT – BASIC PRESSURE….582
PUMP PC CONTROL CIRCUIT….583
PUMP LS CONTROL CIRCUIT….587
SOLENOID VALVE – OUTPUT PRESSURE….592
PPC VALVE – OUTPUT PRESSURE….595
WORK EQUIPMENT PPC VALVE – PLAY ADJUSTMENT….597
SWING PPC VALVE – PLAY ADJUSTMENT….597
WORK EQUIPMENT – HYDRAULIC DRIFT – CAUSE….598
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT….600
MEASURING OIL LEAKAGE….601
BLEEDING AIR FROM EACH PART….604
DIODE TESTING PROCEDURE….607
MONITOR PANEL – SPECIAL FUNCTIONS….608
HANDLING OF ENGINE CONTROLLER….634
PREPARATION WORK FOR TROUBLESHOOTING….635
PM CLINIC SERVICE….637
UNDERCARRIAGE INSPECTION….643
TROUBLESHOOTING GENERAL….644
POINTS TO REMEMBER WHEN TROUBLESHOOTING….646
SEQUENCE OF EVENTS IN TROUBLESHOOTING….648
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….649
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT….649
HANDLING WIRING HARNESSES AND CONNECTORS….649
REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES….651
HANDLING CONTROL BOX….654
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS….655
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT….655
CHECKS BEFORE TROUBLESHOOTING….657
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING….658
CLASSIFICATION OF TROUBLESHOOTING….658
STEPS FOR TROUBLESHOOTING….658
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NOS….659
CONNECTOR ARRANGEMENT DRAWING….662
CONNECTORS LIST….662
CONNECTOR LOCATION DIAGRAM….667
MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT)….673
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM (E CIRCUIT)….674
PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM (P CIRCUIT)….675
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….676
T-BRANCH BOX AND T-BRANCH TABLE….697
CONNECTION TABLE OF FUSE BOX….701
TROUBLESHOOTING ERROR CODES IN MONITOR SYSTEM….702
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM….707
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF….708
USER CODE MEMORY RETENTION FUNCTION….708
INFORMATION CONTAINED IN TESTING PROCEDURES….709
E101….711
ERROR IN DATA HISTORY….711
E112….713
SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM….713
E113….715
SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE….715
E114….717
SHORT OR OPEN IN WINDOW WASHER SYSTEM….717
E115….719
ABNORMAL WIPER MOTOR OPERATION….719
E116….721
ABNORMALITY IN PARKING WIPER ARM….721
E117….723
ENGINE CONTROLLER S-NET COMMUNICATION ERROR….723
E118….725
PUMP CONTROLLER S-NET COMMUNICTION ERROR….725
E128….727
MONITOR COMMUNICATION ABNORMALITY….727
E201….729
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID….729
E203….731
SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM….731
E204….733
SHORT IN MERGE/DIVIDE SOLENOID….733
E205….735
SHORT IN 2-STAGE RELIEF SOLENOID….735
E206….737
SHORT IN TRAVEL SPEED SHIFT SOLENOID….737
E211….739
OPEN IN TRAVEL INTERLOCKING SOLENOID….739
E213….741
OPEN IN SWING HOLDING BRAKE SOLENOID….741
E214….743
OPEN IN MERGE/DIVIDE SOLENOID….743
E215….745
OPEN IN 2-STAGE RELIEF SOLENOID….745
E216….747
OPEN IN TRAVEL SPEED SOLENOID….747
E217….749
ABNORMAL INPUT MODEL CODE….749
E218….751
OPEN IN S-NET COMMUNICATION SIGNAL….751
E222….753
SHORT IN LS-EPC SOLENOID….753
E223….755
OPEN IN LS-EPC SOLENOID SYSTEM….755
E224….757
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL….757
E225….759
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL….759
E226….761
ABNORMAL PRESSURE SENSOR POWER SUPPLY….761
E227….763
ABNORMALITY IN ENGINE ROTATION (RPM) SENSOR….763
E228….765
SHORT IN ATTACHMENT RETURN SWITCHING RELAY….765
E232….767
SHORT IN PC-EPC SOLENOID….767
E233….769
OPEN IN PC-EPC SOLENOID….769
E238….771
OPEN IN ATTACHMENT RETURN SWITCHING RELAY….771
E245….773
SHORT IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM….773
E246….775
OPEN IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM….775
E247….777
ABNORMALITY IN ARM IN PPC PRESSURE SENSOR….777
E248….779
ABNORMALITY IN BUCKET CURL PPC PRESSURE SENSOR….779
E257….781
ABNORMALITY IN PUMP….781
E315….783
SHORT IN BATTERY RELAY SYSTEM….783
E91B….785
ENGNE NE SENSOR PROBLEM….785
E91C….787
ENGINE G SENSOR PROBLEM….787
E920….789
ENGINE TYPE SELECTION ERROR….789
E921….791
ENGINE TYPE MISMATCH….791
E931….793
FUEL DIAL SYSTEM ERROR….793
E934….795
ENGINE COOLANT SENSOR HI ERROR….795
E96A….797
ENGINE COOLANT SENSOR LO ERROR….797
E936….799
ENGINE OIL PRESSURE SWITCH ERROR….799
E93C….801
ENGINE BOOST SENSOR ERROR….801
E93D….803
ENGINE FUEL TEMPERATURE SENSOR ERROR….803
E953….805
ENGINE COMMUNICATION ABNORMALITY….805
E954….807
SHORT IN ENGINE IGNITION SWITCH….807
E955….809
ENGINE S-NET ERROR….809
E956….811
ENGINE POWER FAILURE (1)….811
E957….813
ENGINE POWER FAILURE (2)….813
E95A….815
ENGINE Q-ADJUSTMENT SWITCH SIGNAL ERROR….815
E970….817
PCV1 OVER CURRENT….817
E971….819
PCV2 OVER CURRENT….819
E974….821
PCV1 LINE CUT….821
E975….823
PCV2 LINE CUT….823
E977….825
RAIL PRESSURE SENSOR ERROR….825
E979….827
RAIL PRESSURE HIGH….827
E97A….828
RAIL PRESSURE ABNORMAL HIGH….828
E97B….829
RAIL PRESSURE LOW….829
E97C….831
RAIL PRESSURE TOO LOW….831
E97D….832
RAIL PRESSURE OUT OF CONTROL….832
E980….833
ENGINE CONTROLLER ABNORMALITY….833
E981….835
FUEL INJECTOR 1 DISCONNECTION….835
E982….836
FUEL INJECTOR 2 DISCONNECTION….836
E983….837
FUEL INJECTOR 3 DISCONNECTION….837
E984….838
FUEL INJECTOR 4 DISCONNECTION….838
E985….839
FUEL INJECTOR 5 DISCONNECTION….839
E986….840
FUEL INJECTOR 6 DISCONNECTION….840
E98A….841
FUEL INJECTOR 1 – 3 S/C….841
E98B….843
FUEL INJECTOR 4 – 6 S/C….843
A000N1….845
ENGINE HIGH IDLELING SPEED OUT OF STANDARD….845
A000N2….846
ENGINE LOW IDLING SPEED OUT OF STANDARD….846
AA10NX….847
AIR CLEANER CLOGGED….847
AB00KE….849
CHARGE VOLTAGE LOW….849
B@BAZG….851
ENGINE OIL PRESSURE LOW….851
B@BAZK….853
ENGINE OIL LEVEL LOW….853
B@BCNS….855
ENGINE WATER OVERHEAT….855
B@BCZK….857
ENGINE WATER LEVEL LOW….857
B@HANS….859
HYDRAULIC OIL OVERHEAT….859
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….862
BEFORE CARRYING OUT TROUBLESHOOTING….864
CONNECTION TABLE OF FUSE BOX….864
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM….865
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF….866
USER CODE MEMORY RETENTION FUNCTION….866
INFORMATION CONTAINED IN TESTING PROCEDURES….867
E-1….869
THE ENGINE DOES NOT CRANK….869
E-2….872
PREHEATER DOES NOT OPERATE….872
PREHEATING MONITOR DOES NOT LIGHT….872
HEATER UNIT DOES NOT WARM….873
E-3….875
AUTO ENGINE WARM-UP DEVICE DOES NOT WORK….875
E-4….876
AUTO-DECELERATOR DOES NOT OPERATE….876
E-5….877
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE….877
E-6….879
ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE….879
E-7….881
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY….881
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE….881
MACHINE PUSH-UP FUNCTION IS NOT TURNED OFF….882
E-8….885
ATTACHMENT CIRCUIT DOES NOT CHANGE….885
E-9….887
NO DISPLAY IN MONITOR PANEL AT ALL….887
E-10….889
PART OF DISPLAY ON MONITOR PANEL IS MISSING….889
E-11….889
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL….889
E-12….890
FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING….890
E-13….891
ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY….891
E-14….893
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY….893
E-15….895
FUEL GAUGE DOES NOT DISPLAY CORRECTLY….895
E-16….897
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY….897
E-17….899
WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED….899
E-18….901
WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK….901
WINDSHIELD WIPER DOES NOT WORK….901
WINDSHIELD WASHER DOES NOT OPERATE….903
E-19….905
ALARM BUZZER CANNOT BE CANCELLED….905
E-20….907
“BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….907
E-21….909
“BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….909
E-22….911
“ARM IN” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION….911
E-23….912
“ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….912
E-24….914
“BUCKET CURL” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION….914
E-25….915
“BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….915
E-26….917
“SWING” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION….917
E-27….919
“TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….919
E-28….921
“TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….921
E-29….923
“SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….923
E-30….925
TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING….925
E-32….927
TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM….927
TROUBLESHOOTING PROCEDURE FOR AIR CONDITIONER SYSTEM….927
TROUBLESHOOTING BY SELF-DIAGNOSIS NOTICE….927
E-32-E11 DISCONNECTION IN RECIRCULATED AIR SENSOR….928
E-32-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE….928
E-32-E15 DISCONNECTION IN WATER TEMPERATURE SENSOR….929
E-32-E16 SHORT CIRCUIT IN WATER TEMPERATURE SENSOR….929
E-32-E18 SHORT IN DAYLIGHT SENSOR….930
E-32-E43 ABNORMALITY IN AIR OUTLET DAMPER….930
E-32-E44 ABNORMALITY IN AIR MIX DAMPER….931
E-32-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER….931
E-32 – TROUBLESHOOTING BY FAILURE PHENOMENON….933
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)….938
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS….940
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….942
H-1….943
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW….943
H-2….944
ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS….944
H-3….945
NO WORK EQUIPMENT, TRAVEL OR SWING MOVE….945
H-4….945
ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP….945
H-5….946
AUTO-DECELERATOR DOES NOT WORK….946
H-6….946
FINE CONTROL MODE DOES NOT FUNCTION….946
H-7….947
BOOM MOVES SLOWLY OR LACKS POWER….947
H-8….948
ARM MOVES SLOWLY OR LACKS POWER….948
H-9….949
BUCKET MOVES SLOWLY OR LACKS POWER….949
H-10….949
WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION….949
H-11….950
WORK EQUIPMENT HYDRAULIC DRIFT TOO FAST….950
H-12….951
WORK EQUIPMENT HAS BIG TIME LAG….951
H-13….951
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT….951
H-14….951
ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK….951
H-15….952
MACHINE PUSH-UP FUNCTION DOES NOT WORK….952
H-16….952
IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY….952
H-17….953
IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY….953
H-18….953
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY….953
H-19….954
MACHINE SWERVES IN TRAVEL….954
H-20….955
MACHINE TRAVELS SLOWLY….955
H-21….956
MACHINE CANNOT BE EASILY STEERED OR LACKS POWER….956
H-22….957
TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED….957
H-23….957
TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)….957
H-24….958
MACHINE DOES NOT SWING….958
H-25….959
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW….959
H-26….960
EXCESSIVE OVERRUN WHEN STOPPING SWING….960
H-27….961
THERE IS BIG SHOCK WHEN STOPPING SWING….961
H-28….961
THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING….961
H-29….962
SWING NATURAL DRIFT IS TOO BIG….962
H-30….963
ATTACHMENT CIRCUIT DOES NOT CHANGE….963
H-31….963
FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED….963
30 DISASSEMBLY AND ASSEMBLY….964
HOW TO READ THIS MANUAL….968
REMOVAL AND INSTALLATION OF ASSEMBLIES….968
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES….968
PRECAUTIONS DURING OPERATION….970
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK….970
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK….971
PRECAUTIONS WHEN COMPLETING THE OPERATIONS….972
OTHER PRECAUTIONS….972
SPECIAL TOOL LIST….973
SKETCHES OF SPECIAL TOOLS….978
CONNECTOR REPAIR PROCEDURES….980
CONTACT TERMINAL REMOVAL (HD30 TYPE)….980
STRIPING INSULATION….981
CRIMPING CONTACT TERMINAL (HD30 TYPE)….982
INSERTION OF CONTACT TERMINAL (HD30 TYPE)….983
CONTACT TERMINAL REMOVAL (DT TYPE)….984
STRIPING INSULATION….985
CRIMPING CONTACT TERMINAL (DT TYPE)….986
INSERTION OF CONTACT TERMINAL (DT TYPE)….987
ENGINE….988
AFTERCOOLER….988
ALTERNATOR….988
CYLINDER HEAD….988
ENGINE FRONT SEAL….988
ENGINE OIL COOLER….988
ENGINE REAR SEAL….988
FUEL INJECTION PUMP….988
NOZZLE HOLDER….988
NOZZLE TIP….988
STARTING MOTOR….988
THERMOSTAT….988
TURBOCHARGER….988
WATER PUMP….988
RADIATOR….989
REMOVAL….989
INSTALLATION….991
HYDRAULIC OIL COOLER….992
REMOVAL….992
INSTALLATION….993
ENGINE AND HYDRAULIC PUMP….994
REMOVAL….994
INSTALLATION….999
SWING CIRCLE….1000
REMOVAL….1000
INSTALLATION….1000
SWING MOTOR AND SWING MACHINERY….1001
REMOVAL….1001
INSTALLATION….1002
DISASSEMBLY….1003
ASSEMBLY….1007
SPROCKET….1013
REMOVAL….1013
INSTALLATION….1013
TRAVEL MOTOR AND FINAL DRIVE….1014
REMOVAL….1014
INSTALLATION….1014
FINAL DRIVE….1015
DISASSEMBLY….1015
ASSEMBLY….1020
CARRIER ROLLER….1025
ASSEMBLY….1025
TRACK ROLLER….1027
ASSEMBLY….1027
IDLER….1028
DISASSEMBLY….1028
ASSEMBLY….1029
RECOIL SPRING….1032
DISASSEMBLY….1032
ASSEMBLY….1033
TRACK SHOE….1034
EXPANSION….1034
INSTALLATION….1035
AIR CONDITIONER UNIT….1036
REMOVAL….1036
INSTALLATION….1038
OPERATOR’S CAB….1039
REMOVAL….1039
INSTALLATION….1041
MONITOR….1042
REMOVAL….1042
INSTALLATION….1042
PUMP CONTROLLER….1043
REMOVAL….1043
INSTALLATION….1043
ENGINE CONTROLLER….1044
REMOVAL….1044
INSTALLATION….1044
REVOLVING FRAME….1045
REMOVAL….1045
INSTALLATION….1047
COUNTERWEIGHT….1048
REMOVAL….1048
INSTALLATION….1048
HYDRAULIC TANK….1049
REMOVAL….1049
INSTALLATION….1050
HYDRAULIC PUMP….1051
REMOVAL….1051
INSTALLATION….1053
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT….1054
REMOVAL….1054
INSTALLATION….1054
CONTROL VALVE….1055
REMOVAL….1055
INSTALLATION….1058
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL….1059
ASSEMBLY….1061
CENTER SWIVEL JOINT….1064
REMOVAL….1064
INSTALLATION….1065
DISASSEMBLY….1066
ASSEMBLY….1066
WORK EQUIPMENT PPC VALVE….1067
ASSEMBLY….1067
TRAVEL PPC VALVE….1068
DISASSEMBLY….1068
ASSEMBLY….1068
HYDRAULIC CYLINDER….1069
DISASSEMBLY….1069
ASSEMBLY….1072
WORK EQUIPMENT….1076
REMOVAL….1076
INSTALLATION….1078
OPERATOR’S CAB GLASS….1079
REMOVAL….1080
INSTALLATION….1081
FRONT WINDOW….1090
REMOVAL….1090
INSTALLATION….1093
90 OTHERS….1098
HYDRAULIC….1100
HYDRAULIC DIAGRAM SHEET 1/2 (PART 1 OF 4) FOLDOUT 1….1100
HYDRAULIC DIAGRAM SHEET 1/2 (PART 2 OF 4) FOLDOUT 2….1102
HYDRAULIC DIAGRAM SHEET 1/2 (PART 3 OF 4) FOLDOUT 3….1104
HYDRAULIC DIAGRAM SHEET 1/2 (PART 4 OF 4) FOLDOUT 4….1106
HYDRAULIC DIAGRAM SHEET 2/2 (PART 1 OF 4) FOLDOUT 5….1108
HYDRAULIC DIAGRAM SHEET 2/2 (PART 2 OF 4) FOLDOUT 6….1110
HYDRAULIC DIAGRAM SHEET 2/2 (PART 3 OF 4) FOLDOUT 7….1112
HYDRAULIC DIAGRAM SHEET 2/2 (PART 4 OF 4) FOLDOUT 8….1114
ELECTRICAL….1116
ELECTRICAL DIAGRAM SHEET 1/5 (PART 1 OF 2) FOLDOUT 9….1116
ELECTRICAL DIAGRAM SHEET 1/5 (PART 2 OF 2) FOLDOUT 10….1118
ELECTRICAL DIAGRAM SHEET 2/5 (PART 1 OF 1) FOLDOUT 11….1120
ELECTRICAL DIAGRAM SHEET 3/5 (PART 1 OF 1) FOLDOUT 12….1122
ELECTRICAL DIAGRAM SHEET 4/5 (PART 1 OF 2) FOLDOUT 13….1124
ELECTRICAL DIAGRAM SHEET 4/5 (PART 2 OF 2) FOLDOUT 14….1126
ELECTRICAL DIAGRAM SHEET 5/5 (PART 1 OF 2) FOLDOUT 15….1128
ELECTRICAL DIAGRAM SHEET 5/5 (PART 2 OF 2) FOLDOUT 16….1130
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 17….1132
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 18….1134
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 19….1136
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 20….1138
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 1 OF 4) FOLDOUT 21….1140
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 2 OF 4) FOLDOUT 22….1142
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 3 OF 4) FOLDOUT 23….1144
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 4 OF 4) FOLDOUT 24….1146
Komatsu Hydraulic Excavators PC400LC-L Series Repair Service Manuals