Komatsu PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0 Hydraulic Excavator Shop Manual - SEN03578-01

This complete service repair workshop manual PDF download for the PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0 Komatsu Hydraulic Crawler Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu PC400-7E0 - S/N: 60001-60089
Komatsu PC400LC-7E0 - S/N: 60001-60089
Komatsu PC400-7E0 - S/N: 65001 and up
Komatsu PC400LC-7E0 - S/N: 65001 and up
Komatsu PC450-7E0 - S/N: 30001-30058
Komatsu PC450LC-7E0 - S/N: 30001-30058
Komatsu PC450-7E0 - S/N: 65001 and up
Komatsu PC450LC-7E0 - S/N: 65001 and up


TABLE OF CONTENTS :

- Index and foreword
- Specification
- Structure and function
- Standard value table
- Testing and adjusting
- Troubleshooting
- Disassembly and assembly
- Maintenance standard
- Appendix
- Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN03578-01
Total Pages : 1006


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00 Index and foreword
Index
Organization list of the shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

01 Specification
Specification and technical data
Specification dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard
Engine and cooling system
Engine related parts
Radiator, oil cooler and aftercooler
Power train
Power train
Final drive
Sprocket
Swing machinery
Swing circle
Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Hydraulic system, Part 1
Hydraulic equipment layout drawing
Hydraulic tank and filter
Hydraulic pump
Hydraulic system, Part 2
Control valve
CLSS
Functions and operation by valve
Merge-divider valve
Attachment circuit selector valve
Holding valve
Hydraulic system, Part 3
Valve control
PPC valve
Solenoid valve
PPC accumulator
Return oil filter
Center swivel joint
Travel motor
Swing motor
Hydraulic cylinder
Work equipment
Work equipment
Dimensions of components
Cab and its attachments
Air conditioner piping
Electrical system
Engine control
Electronic control system
Monitor system
Sensor
KOMTRAX terminal system

20 Standard value table
Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts
Standard value table for chassis related parts

30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting and troubleshooting
Measuring engine speed
Measuring air boost pressure
Measuring exhaust temperature
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Handling during cylinder cut-out operation
Handling during no injection cranking operation
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Checking and adjusting fan belt and alternator belt tension
Checking and adjusting air conditioner compressor belt tension
Measuring swing circle bearing clearance
Checking and adjusting track shoe tension
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits
Measuring control circuit basic pressure
Checking and adjusting pump PC control circuit oil pressure
Checking and adjusting pump LS control circuit oil pressure
Measuring solenoid valve output pressure
Measuring PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Inspecting locations of hydraulic drift of work equipment
Releasing residual pressure from hydraulic circuit
Measuring oil leakage amount
Bleeding air from various parts
Testing and adjusting, Part 2
Special functions of machine monitor
Testing and adjusting, Part 3
Procedure for turning on KOMTRAX terminal
Indication by KOMTRAX terminal lamps
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm clinic service
Undercarriage troubleshooting report

40 Troubleshooting
Failure code table and fuse locations
Failure codes table
Before carrying out troubleshooting when failure code is displayed
Information related to troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and troubleshooting steps
Information in troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code), Part 1
Failure code [A000N1] Eng. Hi Out of Std
Failure code [AA10NX] Aircleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng Oil Press. Low
Failure code [B@BAZK] Eng. Oil Level Low
Failure code [B@BCNS] Eng. Water Overheat
Failure code [B@BCZK] Eng. Water Lvl Low
Failure code [B@HANS] Hydr. Oil Overheat
Failure code [CA111] ECM Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA273] PCV2 Short Error
Failure code [CA274] PCV2 Open Error
Failure code [CA322] Inj #1 Open/Short Error
Failure code [CA323] Inj #5 Open/Short Error
Failure code [CA324] Inj #3 Open/Short Error
Failure code [CA325] Inj #6 Open/Short Error
Failure code [CA331] Inj #2 Open/Short Error
Failure code [CA332] Inj #4 Open/Short Error
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Persistent Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1228] EGR Valve Servo Error 1
Failure code [CA1625] EGR Valve Servo Error 2
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Lift Sens High Error
Failure code [CA2272] EGR Valve Lift Sens Low Error
Failure code [CA2351] EGR Valve Sol Current High Error
Failure code [CA2352] EGR Valve Sol Current Low Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [D110KB] Battery Relay Drive S/C
Failure code [D196KA] Service Return Relay Disc.
Failure code [D196KB] Service Return Relay S/C
Failure code [DA25KP] Press. Sensor Power Abnormality
Failure code [DA80MA] Auto. Lub. Abnormal.
Troubleshooting by failure code (Display of code), Part 3
Failure code [DA2RMC] Pump Comm. Abnormality
Failure code [DA2SKQ] Model Selection Abnormality
Failure code [DAFRMC] Monitor Comm. Abnormality
Failure code [DHPAMA] F Pump P. Sensor Abnormality
Failure code [DHPBMA] R Pump P. Sensor Abnormality
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality
Failure code [DHS4MA] Bucket Curl PPC Sen. Abnormality
Failure code [DW43KA] Travel Speed Sol. Disc.
Failure code [DW43KB] Travel Speed Sol. S/C
Failure code [DW45KA] Swing Brake Sol. Disc.
Failure code [DW45KB] Swing Brake Sol. S/C
Failure code [DW91KA] Travel Junction Sol. Disc.
Failure code [DW91KB] Travel Junction Sol. S/C
Failure code [DWJ0KA] Merge-divider Sol. Disc.
Failure code [DWJ0KB] Merge-Divider Sol. S/C
Failure code [DWK0KA] 2-stage Relief Sol. Disc.
Failure code [DWK0KB] 2-stage Relief Sol. S/C
Failure code [DXA0KA] PC-EPC Sol. Disc.
Failure code [DXA0KB] PC-EPC Sol. S/C
Failure code [DXE0KA] LS-EPC Sol. Disc.
Failure code [DXE0KB] LS-EPC Sol. S/C
Failure code [DXE4KA] Service Current EPC Disc.
Failure code [DXE4KB] Service Current EPC S/C
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive S/C
Failure code [DY2DKB] Wiper Drive (For) S/C
Failure code [DY2EKB] Wiper Drive (Rev) S/C
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system
Information contained in troubleshooting table
E-1 Engine does not start
E-2 Auto-decelerator does not operate
E-3 Automatic warming-up does not operate
E-4 Preheater does not operate
E-5 All work equipment, swing, and travel mechanism do not move
E-6 Power maximizing function does not operate
E-7 Machine monitor does not display at all
E-8 Machine monitor does not display some items
E-9 Contents of display by machine monitor are different from applicable machine
E-10 Fuel level monitor was lighted in red while engine running
E-11 Engine coolant temperature gauge does not indicate normally
E-12 Hydraulic oil temperature gauge does not indicate normally
E-13 Fuel level gauge does not operate normally
E-14 Swing lock monitor does not indicate normally
E-15 When monitor switch is operated, monitor displays nothing
E-16 Windowshield wiper does not operate
E-17 Machine push-up function does not operate normally
E-18 Monitoring function fails to display “boom RAISE” normally
E-19 Monitoring function fails to display “boom LOWER” normally
E-20 Monitoring function fails to display “arm IN”normally
E-21 Monitoring function fails to display “arm OUT” normally
E-22 Monitoring function fails to display “bucket CURL”normally
E-23 Monitoring function fails to display “bucket DUMP” normally
E-24 Monitoring function fails to display “swing” normally
E-25 Monitoring function fails to display “travel” normally
E-26 Monitoring function fails to display “travel differential pressure” normally
E-27 Monitoring function fails to display “service” normally
E-28 The KOMTRAX system does not operate normally
E-29 Air conditioner does not operate
E-30 Travel alarm does not sound or does not stop sounding
E-31 Horn does not sound
Troubleshooting of hydraulic and mechanical system (H-mode)
System chart for hydraulic and mechanical system
Information contained in troubleshooting table
H-1 All work equipment lack power, or travel and swing speeds are slow
H-2 Engine speed sharply drops or engine stalls
H-3 No work equipment, swing or travel move
H-4 Abnormal noise is heard from around hydraulic pump
H-5 Auto-decelerator does not work
H-6 Fine control mode does not function or responds slow
H-7 Boom moves slowly or lacks power
H-8 Arm moves slowly or lacks power
H-9 Bucket moves slowly or lacks power
H-10 Work equipment does not move in its single operation
H-11 Work equipment has a bit too fast hydraulic drift
H-12 Work equipment has big time lag
H-13 Other work equipment moves when relieving single circuit
H-14 Power max. switch does not operate
H-15 Machine push-up function does not operate.
H-16 In compound operation of work equipment, speed of part loaded more is low
H-17 When machine swings and raises boom simultaneously, boom rising speed is low
H-18 When machine swings and travels simultaneously, travel speed lowers largely
H-19 Machine deviates during travel
H-20 Travel speed is low
H-21 Machine is not steered well or steering power is low
H-22 Travel speed does not change or travel speed is low or high
H-23 Travel system does not move (only one side)
H-24 Upper structure does not swing
H-25 Swing acceleration or swing speed is low
H-26 Upper structure overruns remarkably when it stops swinging
H-27 Large shock is made when upper structure stops swinging
H-28 Large sound is made when upper structure stops swinging.
H-29 Hydraulic drift of swing is large
H-30 Attachment circuit is not changed
H-31 Oil flow in attachment circuit cannot be controlled
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of engine and hydraulic oil pump assembly
Power train
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Disassembly and assembly of carrier roller assembly
Disassembly and assembly of track roller assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of sprocket
Expansion and installation of track shoe assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Removal and installation of hydraulic pump assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator’s cab
Removal and installation of operator’s cab glass (stuck glass)
Removal and installation of front window assembly
Electrical system
Removal and installation of air conditioner unit assembly
Removal and Installation of KOMTRAX terminal assembly
Removal and installation of monitor assembly
Removal and installation of pump controller

90 Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram
Connector arrangement diagram

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