Komatsu PC400-7, PC400LC-7, PC450-7, PC450LC-7 Hydraulic Excavator Shop Manual SEBM033012

Description

• Model List:
  • PC400-7 Hydraulic Excavator
  • PC400LC-7 Hydraulic Excavator
  • PC450-7 Hydraulic Excavator
  • PC450LC-7 Hydraulic Excavator

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. SPECIFICATION DRAWINGS
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. FUEL, COOLANT AND LUBRICANTS
• 4. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 4.1. ENGINE RELATED PARTS
• 4.2. RADIATOROIL COOLERAFTERCOOLER
• 4.3. POWER TRAIN
• 4.4. FINAL DRIVE
• 4.5. SPROCKET
• 4.6. SWING MACHINERY
• 4.7. SWING CIRCLE
• 4.8. TRACK FRAME AND RECOIL SPRING
• 4.9. IDLER
• 4.10. CARRIER ROLLER
• 4.11. TRACK ROLLER
• 4.12. TRACK SHOE
• 4.13. HYDRAULIC PIPING DRAWING
• 4.14. HYDRAULIC TANK
• 4.15. HYDRAULIC PUMP
• 4.16. LS(PC)EPC VALVE
• 4.17. VARIABLE VOLUME VALVE
• 4.18. CONTROL VALVE
• 4.19. CLSS
• 4.20. FUNCTIONS AND OPERATION BY VALVE
• 4.21. ATTACHMENT CIRCUIT SELECTOR VALVE
• 4.22. HOLDING VALVE
• 4.23. SWING MOTOR
• 4.24. REVERSAL PREVENTION VALVE
• 4.25. CENTER SWIVEL JOINT
• 4.26. TRAVEL MOTOR
• 4.27. VALVE CONTROL
• 4.28. TRAVEL PPC SHUTTLE VALVE
• 4.29. WORK EQUIPMENTSWING PPC VALVE
• 4.30. TRAVEL PPC VALVE
• 4.31. SERVICE PPC VALVE
• 4.32. SOLENOID VALVE
• 4.33. PPC ACCUMULATOR
• 4.34. RETURN OIL FILTER
• 4.35. HYDRAULIC CYLINDER
• 4.36. WORK EQUIPMENT
• 4.37. AIR CONDITIONER
• 4.38. ENGINE CONTROL
• 4.39. ELECTRONIC CONTROL SYSTEM
• 4.40. MONITOR SYSTEM
• 4.41. SEGMENT MONITOR SYSTEM
• 4.42. SENSOR
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE
• 5.2. STANDARD VALUE TABLE FOR CHASSIS (BACKHOE SPECIFICATION)
• 5.3. STANDARD VALUE TABLE FOR CHASSIS (LOADING SHOVEL SPECIFICATION)
• 5.4. TESTING AND ADJUSTING
• 5.4.1. TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
• 5.4.2. MEASURING ENGINE SPEED
• 5.4.3. MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
• 5.4.4. MEASURING EXHAUST TEMPERATURE
• 5.4.5. MEASURING EXHAUST GAS COLOR
• 5.4.6. ADJUSTING VALVE CLEARANCE
• 5.4.7. MEASURING COMPRESSION PRESSURE
• 5.4.8. MEASURING BLOWBY PRESSURE
• 5.4.9. MEASURING ENGINE OIL PRESSURE
• 5.4.10. HANDLING OF FUEL SYSTEM DEVICES
• 5.4.11. RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
• 5.4.12. MEASURING FUEL PRESSURE
• 5.4.13. BLEEDING AIR FROM FUEL CIRCUIT
• 5.4.14. INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
• 5.4.15. ADJUSTING ENGINE SPEED SENSOR
• 5.4.16. TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION
• 5.4.17. TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
• 5.4.18. MEASURING CLEARANCE OF SWING CIRCLE BEARING
• 5.4.19. TESTING AND ADJUSTING TRACK SHOE TENSION
• 5.4.20. TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
• 5.4.21. MEASURING BASIC PRESSURE IN CONTROL CIRCUIT
• 5.4.22. TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
• 5.4.23. TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
• 5.4.24. MEASURING SOLENOID VALVE OUTPUT PRESSURE
• 5.4.25. MEASURING PPC VALVE OUTPUT PRESSURE
• 5.4.26. ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES
• 5.4.27. TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
• 5.4.28. RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
• 5.4.29. MEASURING OIL LEAKAGE
• 5.4.30. BLEEDING AIR FROM EACH PART
• 5.4.31. TESTING PROCEDURE OF DIODE
• 5.4.32. SPECIAL FUNCTIONS OF MONITOR PANEL
• 5.4.33. SPECIAL FUNCTIONS OF 7SEGMENTS MONITOR PANEL
• 5.4.34. HANDLING OF HIGHVOLTAGE CIRCUIT OF ENGINE CONTROLLER
• 5.4.35. PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM
• 5.4.36. PMCLINIC SERVICE
• 5.5. TROUBLESHOOTING
• 5.5.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.5.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.5.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 5.5.4. CHECKS BEFORE TROUBLESHOOTING
• 5.5.5. CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
• 5.5.6. CONNECTOR ARRANGEMENT DIAGRAM AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
• 5.5.7. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 5.5.8. T BRANCH BOX AND T BRANCH ADAPTER TABLE
• 5.5.9. CONNECTION TABLE OF FUSE BOX
• 5.5.10. TROUBLESHOOTING WHEN ERROR CODE ELECTRICAL SYSTEM AND FAILURE CODE MECHANICAL SYSTEM ARE DISPLAYED
• 5.5.11. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 5.5.12. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H MODE)
• 5.5.13. TROUBLESHOOTING OF ENGINE (S MODE)
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. HOW TO READ THIS MANUAL
• 6.2. COATING MATERIALS LIST
• 6.3. SPECIAL TOOL LIST
• 6.4. REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
• 6.5. REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
• 6.6. REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
• 6.7. REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
• 6.8. REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
• 6.9. REMOVAL AND INSTALLATION OF NOZZLE TIP
• 6.10. REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY
• 6.11. REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
• 6.12. REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
• 6.13. REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY
• 6.14. REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY
• 6.15. REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY
• 6.16. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY
• 6.17. REMOVAL AND INSTALLATION OF SPROCKET
• 6.18. REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
• 6.19. DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
• 6.20. DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY
• 6.21. DISASSEMBLY AND ASSEMBLY OF TRAVEL ROLLER ASSEMBLY
• 6.22. DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
• 6.23. DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
• 6.24. EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY
• 6.25. REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
• 6.26. REMOVAL AND INSTALLATION OF OPERATORS CAB
• 6.27. REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY
• 6.28. REMOVAL AND INSTALLATION OF PUMP CONTROLLER
• 6.29. REMOVAL AND INSTALLATION OF ENGINE CONTROLLER
• 6.30. REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY
• 6.31. REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY
• 6.32. REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
• 6.33. REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
• 6.34. REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
• 6.35. REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY
• 6.36. DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY
• 6.37. REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY
• 6.38. DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
• 6.39. DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
• 6.40. DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY
• 6.41. DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
• 6.42. REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY
• 6.43. REMOVAL AND INSTALLATION OF OPERATORS CAB GLASS (STUCK GLASS)
• 6.44. REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY
• 7. OTHERS
• 7.1. HYDRAULIC CIRCUIT DIAGRAM (1/2)
• 7.2. HYDRAULIC CIRCUIT DIAGRAM (2/2)
• 7.3. ELECTRICAL CIRCUIT DIAGRAM (1/6)
• 7.4. ELECTRICAL CIRCUIT DIAGRAM (2/6)
• 7.5. ELECTRICAL CIRCUIT DIAGRAM (3/6)
• 7.6. ELECTRICAL CIRCUIT DIAGRAM (4/6)
• 7.7. ELECTRICAL CIRCUIT DIAGRAM (5/6)
• 7.8. ELECTRICAL CIRCUIT DIAGRAM (6/6)
• 7.9. AIR CONDITIONER ELECTRICAL CIRCUIT
• 7.10. ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)
• 7.11. CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)