Komatsu Hydraulic Excavators PC400LC-LM, PC400HD-LM Series Repair Service Manuals
Catalog:
Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC400LC-6LM, PC400HD-6LM, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC400LC-6LM, PC400HD-6LM 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.
CEAM008000 - Hydraulic Excavator PC400LC-6LM, PC400HD-6LM Operation & Maintenance Manual.pdf
CEBM005302 - Hydraulic Excavator PC400LC-6LM, PC400HD-6LM Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,157 pages
File Format: PDF
Language: English
CEAM008000 - Hydraulic Excavator PC400LC-6LM, PC400HD-6LM Operation & Maintenance Manual...2
COVER...2
INTRODUCTION...8
FOREWORD...9
SAFETY INFORMATION...9
INTRODUCTION...10
INTENDED USE...10
FEATURES...10
BREAKING IN THE MACHINE...10
LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR...11
P.I.N. PLATE LOCATION...11
ENGINE SERIAL NO. PLATE LOCATION...11
TABLE TO ENTER NUMBERS AND DISTRIBUTOR...11
TABLE OF CONTENTS...12
SAFETY...20
WARNING LABELS...21
GENERAL PRECAUTIONS...26
SAFETY RULES...26
SAFETY FEATURES...26
UNAUTHORIZED MODIFICATION...26
INSIDE OPERATOR’S COMPARTMENT...26
CLOTHING AND PERSONAL PROTECTIVE ITEMS...27
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT...27
MOUNTING AND DISMOUNTING...27
INJURY FROM WORK EQUIPMENT...28
FIRE PREVENTION FOR FUEL AND OIL...28
PRECAUTIONS AT HIGH TEMPERATURES...28
ASBESTOS DUST HAZARD PREVENTION...29
FIRE EXTINGUISHER AND FIRST AID KIT...29
CAB GLASS...29
WINDOW WASHER FLUID...29
ESCAPE FROM FIRE...29
PROTECTION AGAINST FALLING OR FLYING OBJECTS...30
MACHINES WITH ACCUMULATOR...30
PRECAUTIONS FOR ATTACHMENTS...30
INDOOR VENTILATION...31
EMERGENCY EXIT FROM OPERATORS CAB...31
PRECAUTIONS DURING OPERATION...32
BEFORE STARTING ENGINE...32
SAFETY AT WORK SITE...32
FIRE PREVENTION...32
VENTILATION FOR ENCLOSED AREAS...32
IN OPERATOR’S CAB...33
PRECAUTIONS FOR MIRROR AND LIGHTS...33
WHEN STARTING ENGINE...33
OPERATING MACHINE...34
WHEN STARTING ENGINE...34
CHECK DIRECTION BEFORE STARTING MACHINE...34
CHECK THAT NO ONE IS IN AREA BEFORE SWINGING OR TRAVELING IN REVERSE...34
NEVER LET ANYONE RIDE ON ATTACHMENT...34
PRECAUTIONS WHEN TRAVELING...35
OPERATE CAREFULLY ON SNOW...35
TRAVELING ON SLOPES...36
PROHIBITED OPERATIONS...36
PRECAUTIONS FOR OPERATION...37
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...37
WORKING ON LOOSE GROUND...38
OPERATING ON SLOPES...38
PARKING THE MACHINE...38
PRECAUTIONS IN COLD WEATHER...39
TRANSPORTATION...40
LOADING AND UNLOADING...40
PRECAUTIONS WHEN LIFTING...40
SHIPPING...41
BATTERY...42
BATTERY HAZARD PREVENTION...42
STARTING WITH BOOSTER CABLES...42
CHARGING BATTERY...43
TOWING...44
PRECAUTIONS WHEN TOWING...44
BUCKET WITH HOOK...45
PROHIBITED OPERATIONS...45
PRECAUTIONS WHEN INSTALLING AND OPERATING BUCKET WITH HOOK...45
PRECAUTIONS FOR MAINTENANCE...46
BEFORE CARRYING OUT MAINTENANCE...46
CONTACT WHEN THERE IS FAILURE...46
WARNING TAG...46
CLEAN BEFORE INSPECTION OR MAINTENANCE...46
NEAT CLEAN WORK PLACE...46
FOLLOW LEADER IN OPERATIONS WITH OTHER WORKERS...46
RADIATOR COOLANT LEVEL...47
DO NOT DISASSEMBLE RECOIL SPRING...47
PROPER TOOLS...47
STOP ENGINE PRIOR TO INSPECTION AND MAINTENANCE...47
SUPPORT FOR WORK EQUIPMENT...48
PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS...48
USE OF LIGHTING...48
FIRE PREVENTION...48
RULES TO FOLLOW WHEN ADDING FUEL OR OIL...49
DURING MAINTENANCE...50
PERSONNEL...50
REMOVAL, INSTALLATION AND STORAGE OF ATTACHMENTS...50
WORK UNDER THE MACHINE...50
NOISE...50
WHEN WORKING ON MACHINE...50
LOCK INSPECTION COVERS...50
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...51
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE...51
FLYING PIECES WITH HAMMER WORK...51
KEEP THE MACHINE CLEAN...51
WELDING REPAIRS...52
REMOVE BATTERY TERMINALS...52
ACTION WHEN ABNORMALITY IS FOUND DURING INSPECTION...52
RULES TO FOLLOW WHEN ADDING FUEL...52
PRECAUTIONS WHEN ADJUSTING TRACK TENSION...53
HANDLING HIGH PRESSURE HOSES...53
PRECAUTIONS WITH HIGH PRESSURE OIL...53
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR PRESSURE...54
WASTE MATERIALS...54
CHECKS AFTER INSPECTION AND MAINTENANCE...54
MAINTENANCE FOR AIR CONDITIONER...54
OPERATION...56
GENERAL...57
GENERAL VIEW OF MACHINE...57
GENERAL VIEW OF OPERATORS COMPARTMENT...58
GENERAL VIEW OF MONITOR PANEL...59
EXPLANATION OF COMPONENTS...60
MACHINE MONITOR...60
MONITOR LIGHT GROUP...62
METER DISPLAY PORTION...64
SWITCHES...67
SWITCHES...70
CONTROL LEVERS AND PEDALS...75
ATTACHMENT CONTROLS...78
ROOF VENT...80
WHEN OPENING...80
WHEN CLOSING...80
FRONT WINDOW...81
WHEN OPENING...81
WHEN CLOSING...82
FRONT BOTTOM WINDOW...83
DOOR LOCK...84
CAP, COVER WITH LOCK...85
METHOD OF OPENING AND CLOSING LOCK CAP...85
METHOD OF OPENING AND CLOSING COVER LOCK...85
OPERATOR EASE...86
HOT AND COOL BOX...86
STORAGE BOX...86
ASHTRAY...86
AIR CONDITIONER...87
GENERAL LOCATIONS ON CONTROL PANEL...87
PRECAUTIONS WHEN USING AIR CONDITIONER...89
CHECK, MAINTAIN MACHINE WITH AIR CONDITIONER...89
CAB HEATER...90
GENERAL LOCATION...90
HEATER FAN SWITCH...90
VENT SELECTOR SWITCH...91
DEFROSTER SELECTOR LEVER...91
PREPARATION FOR HEATER...92
AM/FM RADIO...93
EXPLANATION OF COMPONENTS...93
METHOD OF OPERATION...95
PRECAUTIONS WHEN USING...97
SPECIFICATIONS...97
ELECTRIC POWER TAKE OUT ADAPTER...98
FUSE...99
FUSIBLE LINK...100
CONTROLLERS...100
TOOL BOX...100
GREASE GUN HOLDER...100
HANDLING ACCUMULATOR...101
METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR...101
OPERATION...102
CHECK BEFORE STARTING ENGINE...102
WALK AROUND CHECK...102
CHECK BEFORE STARTING...104
ADJUST SEAT BEFORE OPERATION...107
SEAT BELT...110
ADJUSTMENT OF MONITOR PANEL ANGLE...110
ADJUSTMENT OF MIRRORS...110
OPERATIONS AND CHECKS BEFORE STARTING ENGINE...111
STARTING ENGINE...113
NORMAL STARTING...113
STARTING IN COLD WEATHER...114
OPERATIONS AND CHECKS AFTER STARTING ENGINE...116
WHEN NORMAL...116
IN COLD AREAS (AUTOMATIC WARM UP OPERATION)...118
MOVING MACHINE...122
MOVING MACHINE FORWARD...122
MOVING MACHINE REARWARD...123
STEERING MACHINE...125
STEERING (CHANGING DIRECTION)...125
STOPPING MACHINE...127
SWINGING...128
OPERATION OF WORK EQUIPMENT...129
HANDLING ACTIVE MODE...130
HANDLING WORKING MODE...131
WORKING MODE...131
POWER MAX., SWIFT SLOW DOWN...131
PROHIBITIONS FOR OPERATION...133
PROHIBITED OPERATIONS USING SWING FORCE...133
PROHIBITED OPERATIONS USING TRAVEL FORCE...133
PRECAUTIONS WHEN OPERATING CYLINDERS TO END OF STROKE...133
PROHIBITED OPERATIONS USING DROPPING FORCE OF BUCKET...134
PROHIBITED OPERATIONS USING DROPPING FORCE OF MACHINE...134
DIGGING ROCKY GROUND...134
SUDDEN LEVER SHIFTING DURING HI SPEED TRAVEL PROHIBITED...134
PRECAUTIONS FOR OPERATION...135
PRECAUTIONS WHEN TRAVELING...135
PRECAUTIONS AT HI SPEED TRAVEL...135
PERMISSIBLE WATER DEPTH...135
PRECAUTIONS WHEN TRAVELING ON HILLS...136
BRAKING WHEN TRAVELING DOWNHILL...137
IF SHOES SLIP...137
IF ENGINE STOPS...137
PRECAUTIONS ON SLOPES...137
HOW TO ESCAPE FROM MUD...138
WHEN ONE SIDE IS STUCK...138
WHEN BOTH SIDES ARE STUCK...138
WORK POSSIBLE USING EXCAVATOR...139
BACKHOE WORK...139
SHOVEL WORK...139
DITCHING WORK...139
LOADING WORK...140
BUCKET REPLACEMENT OR INVERSION...141
REPLACEMENT...141
INVERSION...142
PARKING MACHINE...143
CHECK AFTER FINISHING WORK...145
STOPPING ENGINE...145
CHECK AFTER STOPPING ENGINE...145
LOCKING...146
TRANSPORTATION...147
TRANSPORTATION PROCEDURE...147
LOADING, UNLOADING WORK ON TRAILERS...147
LOADING...148
UNLOADING...149
SECURING MACHINE...151
REMOVAL, INSTALLATION OF MIRRORS...152
METHOD OF LIFTING MACHINE...152
TRACK FRAME GAUGE...154
REDUCING TRACK GAUGE...154
INCREASING TRACK GAUGE...154
COLD WEATHER OPERATION...155
PRECAUTIONS FOR LOW TEMPERATURE...155
FUEL AND LUBRICANTS...155
COOLANT...155
BATTERY...156
PRECAUTIONS AFTER COMPLETION OF WORK...157
AFTER COLD WEATHER...157
LONG TERM STORAGE...158
BEFORE STORAGE...158
DURING STORAGE...158
AFTER STORAGE...158
MACHINE START AFTER LONG TERM STORAGE...159
TROUBLESHOOTING...160
PHENOMENA THAT ARE NOT FAILURES...160
METHOD OF TOWING DISABLED MACHINE...160
USING MACHINE FOR LIGHT WEIGHT TOWING...160
PRECAUTIONS ON PARTICULAR JOB SITES...160
DISCHARGED BATTERY...161
REMOVING AND INSTALLING BATTERY...161
PRECAUTIONS FOR CHARGING BATTERY...161
STARTING ENGINE WITH BOOSTER CABLE...162
OTHER TROUBLE...164
ELECTRICAL SYSTEM...164
CHASSIS...165
ENGINE...166
ELECTRONIC CONTROL SYSTEM...167
MAINTENANCE...168
GUIDES TO MAINTENANCE...169
OUTLINES OF SERVICE...171
OUTLINE OF OIL, FUEL, COOLANT...171
OIL...171
FUEL...171
COOLANT...172
GREASE...172
STORING OIL AND FUEL...172
FILTERS...172
RELATING TO ELECTRICAL SYSTEM...172
OUTLINE OF HYDRAULIC SYSTEM...173
WEAR PARTS LIST...174
USE OF FUEL, COOLANT AND LUBRICANTS...175
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...175
ABBREVIATIONS...175
ENGINE OIL SPECIFICATIONS...176
NORMAL OPERATION...176
ARCTIC OPERATION...176
DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYD....177
FINAL DRIVE OIL SPECIFICATIONS...177
FUEL SYSTEM...177
COOLING SYSTEM...178
GENERAL...178
WATER...178
ANTIFREEZE...178
INHIBITORS/CONDITIONERS...179
SUPPLEMENTAL COOLANT ADDITIVES...179
STANDARD TIGHTENING TORQUES...183
INTRODUCTION OF NECESSARY TOOLS...183
BOLT IDENTIFICATION CHART...184
PERIODIC REPLACEMENT OF CRITICAL PARTS...185
MAINTENANCE SCHEDULE CHART...186
MAINTENANCE INTERVAL WHEN USING BREAKER...188
SERVICE PROCEDURE...189
INITIAL 250 HOURS SERVICE...189
FUEL FILTER CARTRIDGE...189
ENGINE VALVE CLEARANCE...190
WHEN REQUIRED...191
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...191
DRAIN, FLUSH AND REFILL COOLING SYSTEM...193
CHECK AND TIGHTEN TRACK SHOE BOLTS...195
CHECK AND ADJUST TRACK TENSION...196
CHECK ELECTRICAL INTAKE AIR HEATER...198
BUCKET TEETH REPLACEMENT...198
ADJUST BUCKET CLEARANCE...200
CHECK WINDOW WASHER FLUID, ADD FLUID...201
CHECK, MAINTAIN AIR CONDITIONER...202
REPLACE ADDITIONAL BREAKER FILTER ELEMENT...203
CLEAN IN LINE FILTERS...204
CHECK BEFORE STARTING...205
CHECK COOLANT LEVEL, ADD COOLANT...205
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...205
CHECK FUEL LEVEL, ADD FUEL...206
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...206
CHECK AIR CLEANER FOR CLOGGING...207
CHECK ELECTRIC WIRING...207
CHECK FUNCTION OF HORN...207
CHECK FOR WATER AND SEDIMENT IN FUEL FILTER, DRAIN...208
EVERY 50 HOURS SERVICE...209
GREASE LUBRICATION...209
EVERY 100 HOURS SERVICE...211
LUBRICATION...211
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...212
DRAIN WATER AND SEDIMENT FROM FUEL TANK...212
EVERY 250 HOURS SERVICE...213
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...213
CHECK LEVEL OF BATTERY ELECTROLYTE...213
CHANGE ENGINE OIL, REPLACE FILTER CARTRIDGE...214
LUBRICATE SWING CIRCLE (3 POINTS)...215
CHECK FAN BELT TENSION, ADJUST...215
CHECK, ADJUST TENSION OF A/C COMPRESSOR BELT...216
EVERY 500 HOURS SERVICE...218
REPLACE FUEL FILTER CARTRIDGE...218
CHECK SWING PINION GREASE LEVEL, ADD GREASE...219
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, CONDENSER FINS...220
CLEAN FILTERS OF AIR CONDITIONER...220
REPLACE HYDRAULIC TANK BREATHER ELEMENT...221
REPLACE HYDRAULIC FILTER ELEMENT...221
EVERY 1000 HOURS SERVICE...223
CHANGE OIL IN SWING MACHINERY CASE...223
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...223
CHECK TIGHTENING PARTS OF TURBOCHARGER...224
CHECK PLAY OF TURBOCHARGER ROTOR...224
REPLACE CORROSION RESISTOR CARTRIDGE...224
EVERY 2000 HOURS SERVICE...226
CHANGE OIL IN FINAL DRIVE CASE...226
CLEAN HYDRAULIC TANK STRAINER...226
CLEAN ENGINE BREATHER...227
CLEAN, CHECK TURBOCHARGER...227
CHECK ALTERNATOR, STARTING MOTOR...227
CHECK ENGINE VALVE CLEARANCE, ADJUST...227
CHECK VIBRATION DAMPER...227
CHECK, ADJUST FUEL INJECTION NOZZLES...227
EVERY 4000 HOURS SERVICE...228
CHECK WATER PUMP...228
REPLACE FUEL INJECTION NOZZLE TIPS...228
EVERY 5000 HOURS SERVICE...229
CHANGE OIL IN HYDRAULIC TANK...229
SPECIFICATIONS...234
SPECIFICATIONS AND DIMENSIONS...235
SPECIFICATIONS...235
PC400LC-6KE...235
WORKING RANGE...239
LIFTING CAPACITY - STANDARD GAUGE TRACK...241
LIFTING CAPACITY - VARIABLE GAUGE TRACK...245
PC400HD-6KE...249
WORKING RANGE...251
LIFTING CAPACITY...253
OPTIONS, ATTACHMENTS...258
GENERAL PRECAUTIONS...259
PRECAUTIONS RELATED TO SAFETY...259
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...260
BUCKET WITH HOOK...261
CHECKING FOR DAMAGE...261
PROHIBITED OPERATIONS...261
PRECAUTIONS DURING OPERATIONS...261
MACHINES READY FOR ATTACHMENT...262
GENERAL LOCATIONS...262
HYDRAULIC CIRCUIT...264
SWITCHING TO FILTER CIRCUIT...264
CONNECTING HYDRAULIC CIRCUIT...264
PATH OF OIL FLOW...265
ATTACHMENT REMOVAL AND INSTALLATION...266
PROCEDURE FOR REMOVAL...266
PROCEDURE FOR INSTALLATION...266
OPERATION...267
WHEN USING BREAKER...267
WHEN USING GENERAL ATTACHMENT...267
LONG TERM STORAGE...268
SPECIFICATIONS...268
INTRODUCTION OF ATTACHMENTS...269
ATTACHMENT INSTALLATION COMBINATION TABLE...269
BUCKET SELECTION...270
STANDARD DUTY PLATE BUCKET...270
HEAVY DUTY PLATE BUCKET...270
HEAVY DUTY CAST BUCKET...270
DITCH CLEANING BUCKET...270
SELECTION OF TRACK SHOES...271
EXTENDING MACHINE SERVICE LIFE...272
HYDRAULIC BREAKER...272
MAIN FIELDS OF APPLICATION...272
MISTAKEN METHODS OF USE...273
GREASING POSITION FOR HYDRAULIC BREAKER...275
POWER RIPPER...276
MAIN FIELDS OF APPLICATION...276
MISTAKEN METHODS OF USE...276
GRAB FORK...278
MAIN FIELDS OF APPLICATION...278
MISTAKEN METHODS OF USE...278
GRAPPLE BUCKET...279
MAIN FIELDS OF APPLICATION...279
MISTAKEN METHODS OF USE...279
SCRAP GRAPPLE...281
MAIN FIELDS OF APPLICATION...281
MISTAKEN METHODS OF USE...281
CRUSHER AND CUTTER...283
MAIN FIELDS OF APPLICATION...283
MISTAKEN METHODS OF USE...283
HYDRAULIC PILE DRIVER...284
MAIN FIELDS OF APPLICATION...284
MISTAKEN METHODS OF USE...284
MULTIPURPOSE CRANE...286
MAIN FIELDS OF APPLICATION...286
MISTAKEN METHODS OF USE...286
CEBM005302 - Hydraulic Excavator PC400LC-6LM, PC400HD-6LM Shop Manual...290
COVER...290
CONTENTS...291
SAFETY...302
SAFETY NOTICE...302
IMPORTANT SAFETY NOTICE...302
GENERAL PRECAUTIONS...302
PREPARATIONS FOR WORK...302
PRECAUTIONS DURING WORK...302
FOREWORD...304
GENERAL...304
HOW TO READ THE SHOP MANUAL...305
VOLUMES...305
DISTRIBUTION AND UPDATING...305
FILING METHOD...305
REVISED EDITION MARK...305
REVISIONS...305
SYMBOLS...305
HOISTING INSTRUCTIONS...306
HOISTING...306
WIRE ROPES...306
COATING MATERIALS...307
STANDARD TIGHTENING TORQUE...309
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...309
TIGHTENING TORQUE OF HOSE NUTS...310
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...310
TIGHTENING TORQUE FOR FLARED NUTS...310
ALTERNATIVE FASTENERS...311
BOLT IDENTIFICATION CHART...311
GRADE 5 AND 8 NON PHOSPHATE COATED HARDWARE...312
GRADE 8 PHOSPHATE COATED HARDWARE...313
STANDARD METRIC FASTENERS...313
HYDRAULIC TUBES AND FITTINGS...314
HOSE CLAMPS...314
SPLIT FLANGE CONNECTIONS...314
ELECTRIC WIRE CODE...315
CLASSIFICATION BY THICKNESS...315
CLASSIFICATION BY COLOR AND CODE...315
CONVERSION TABLES...316
METHOD OF USING THE CONVERSION TABLE...316
01 GENERAL...322
SPECIFICATION DRAWINGS...323
MACHINE...323
WORK EQUIPMENT...325
SPECIFICATIONS...327
WEIGHT TABLE...329
FUEL COOLANT AND LUBRICANTS...331
ENGINE OIL SPECIFICATIONS...332
NORMAL OPERATION...332
ARCTIC OPERATION...332
FINAL DRIVE OIL SPECIFICATIONS...333
COOLANT SPECIFICATIONS...334
10 STRUCTURE AND FUNCTION...340
PARTS RELATED TO ENGINE...341
RADIATOR, OIL COOLER...343
POWER TRAIN...344
FINAL DRIVE...345
SWING CIRCLE...346
SWING MACHINERY...347
TRACK FRAME, RECOIL SPRING...348
PC400LC-6LM...348
TRACK FRAME, RECOIL SPRING...349
PC400LC-6LM - Variable Gauge...349
TRACK FRAME, RECOIL SPRING...350
PC400HD-6LM...350
TRACK SHOE...351
HYDRAULIC PIPING DRAWING...352
HYDRAULIC CIRCUIT DIAGRAM...353
HYDRAULIC TANK, HYDRAULIC FILTER...354
HYDRAULIC PUMP...355
MAIN PUMP...356
TVC, LS VALVE...361
CONTROL VALVE...375
STANDARD AND 2 SERVICE VALVES...375
MAIN STRUCTURE OF 9 SPOOL VALVE (1/4)...376
MAIN STRUCTURE OF 9 SPOOL VALVE (2/4)...377
MAIN STRUCTURE OF 9 SPOOL VALVE (3/4)...378
MAIN STRUCTURE OF 9 SPOOL VALVE (4/4)...379
9 SPOOL VALVE - STD AND 2 SERVICE VALVES...381
8 SPOOL VALVE - STD AND 1 SERVICE VALVES...382
7 SPOOL VALVE - STD...383
SELF REDUCING PRESSURE VALVE...384
STRUCTURE...384
WHEN ENGINE IS STOPPED...386
AT NEUTRAL AND WHEN LOAD PRESSURE P2 IS LOW...387
WHEN LOAD PRESSURE P2 IS HIGH...387
WHEN THERE IS ABNORMAL HIGH PRESSURE...388
SUCTION SAFETY VALVE...389
FOR SERVICE VALVE...389
CLSS...390
OUTLINE OF CLSS...390
BASIC PRINCIPLE...391
CONTROL OF PUMP SWASH PLATE ANGLE...391
PRESSURE COMPENSATION...392
WHEN UNLOAD VALVE IS ACTUATED...396
CUT-OFF CONTROL ACTUATED...397
CUT-OFF CANCELED...397
INTRODUCTION OF LS PRESSURE...398
LS BYPASS VALVE...399
PRESSURE COMPENSATION VALVE...400
SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE...403
VARIABLE TYPE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE)...405
BOOM REGENERATION CIRCUIT...406
ARM REGENERATION CIRCUIT...408
MERGE FLOW DIVIDER VALVE...409
LS SELECT VALVE...411
2-STAGE SAFETY VALVE (INSTALLED TO BOOM CYLINDER HEAD)...412
WHEN ALL WORK EQUIPMENT IS AT NEUTRAL (10-75)...413
WHEN PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY (10-76)...416
WHEN PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY (10-79)...417
WHEN PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY (10-80)...420
WHEN PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY (10-83)...421
WHEN PUMP DIVIDED, TRAVEL OPERATED INDEPENDENTLY (10-84)...424
WHEN PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY (10-87)...425
WHEN PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY (10-88)...428
WHEN PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY (10-91)...429
WHEN PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY (10-92)...432
SWING MOTOR...433
KMF160ABE-3...433
SUCTION-SAFETY VALVE...435
SWING BRAKE...436
CENTER SWIVEL JOINT...437
TRAVEL MOTOR...438
OPERATION OF MOTOR...440
AT LOW SPEED...440
AT HIGH SPEED...441
OPERATION OF PARKING BRAKE...442
COUNTERBALANCE VALVE, CHECK VALVE...443
SAFETY VALVE...444
VALVE CONTROL...447
WORK EQUIPMENT PPC VALVE...448
OPERATION...450
TRAVEL PPC VALVE...452
OPERATION...454
SERVICE PPC VALVE...456
PPC SAFETY LOCK VALVE...458
PPC ACCUMULATOR...459
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE...460
PPC SHUTTLE VALVE...461
TRAVEL JUNCTION VALVE...464
STRAIGHT-TRAVEL SYSTEM...465
LS-EPC VALVE...467
FUNCTION...468
OPERATION...468
SOLENOID VALVE...470
WHEN SOLENOID IS DEACTIVATED...471
WHEN SOLENOID IS EXCITED...471
BOOM HOLDING VALVE...472
OPERATION...473
BOOM LEVER AT HOLD...473
AT BOOM LOWER...474
WORK EQUIPMENT...475
AIR CONDITIONER...476
AIR CONDITIONER PIPING...476
ACTUAL ELECTRICAL WIRING DIAGRAM...477
ENGINE CONTROL...483
OPERATION OF SYSTEM...484
COMPONENTS OF SYSTEM...485
ELECTRONIC CONTROL SYSTEM...489
CONTROL FUNCTION...489
PUMP AND ENGINE MUTUAL CONTROL SYSTEM...491
CONTROL METHOD IN EACH MODE...492
PUMP AND VALVE CONTROL FUNCTION...494
FUNCTION...494
LS CONTROL FUNCTION...494
CUT-OFF FUNCTION...495
CUT-OFF CANCEL FUNCTION...495
FINE CONTROL MODE FUNCTION...496
POWER MAX. FUNCTION, SWIFT SLOW-DOWN FUNCTION...497
FUNCTION...497
POWER MAX. FUNCTION...497
SWIFT SLOW-DOWN FUNCTION...497
AUTO DECELERATION SYSTEM...498
FUNCTION...498
OPERATION...499
AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION...500
FUNCTION...500
ENGINE AUTOMATIC WARMING-UP FUNCTION...501
ENGINE OVERHEAT PREVENTION FUNCTION...501
SWING CONTROL SYSTEM...502
FUNCTION...502
SWING LOCK, SWING HOLDING BRAKE FUNCTION...503
HYDRAULIC OIL QUICK WARM-UP FUNCTION WHEN SWING LOCK SWITCH IS ON...503
TRAVEL CONTROL SYSTEM...504
FUNCTION...504
PUMP CONTROL FUNCTION WHEN TRAVELING...505
TRAVEL SPEED SELECTION FUNCTION...505
ACTIVE MODE FUNCTION...506
FUNCTION...506
INCREASE IN ENGINE SPEED...507
2-STAGE BOOM LOWERING SPEED...507
2-STAGE STROKE FOR SWING SPOOL...507
COMPONENTS OF SYSTEM...508
ENGINE SPEED SENSOR...508
PPC HYDRAULIC SWITCH...508
PUMP PRESSURE SENSOR...509
TVC PROLIX RESISTOR...510
MACHINE MONITOR SYSTEM...511
MONITOR PANEL...512
OUTLINE...512
INPUT AND OUTPUT SIGNALS...512
MONITOR DISPLAY...513
CONTENT OF DISPLAY...514
OIL MAINTENANCE FUNCTION...515
ELAPSED TIME RESET...516
DEMO MODE...516
MODE SELECTION SWITCHES...517
SWITCH ACTUATION TABLE...517
SENSORS...518
ENGINE OIL LEVEL SENSOR...519
HYDRAULIC OIL LEVEL SENSOR...519
ENGINE OIL PRESSURE SENSOR (BOTH LO AND HI)...519
COOLANT TEMPERATURE SENSOR...519
FUEL LEVEL SENSOR...520
AIR CLEANER CLOGGING SENSOR...520
20 TESTING, ADJUSTING AND TROUBLESHOOTING...522
STANDARD VALUE TABLE...523
FOR ENGINE...523
FOR CHASSIS RELATED PARTS...524
FOR ELECTRICAL PARTS...529
SERVICE TOOLS TABLE...534
MEASURING ENGINE SPEED...535
MEASURING EXHAUST COLOR...536
MEASURING WITH HANDY SMOKE CHECKER H1...536
MEASURING WITH SMOKE METER H2...536
VALVE CLEARANCE...537
COMPRESSION PRESSURE...538
BLOW BY PRESSURE...539
FUEL INJECTION TIMING...540
ADJUSTING...541
ENGINE OIL PRESSURE...542
FAN BELT TENSION...543
A/C COMPRESSOR BELT...544
ENGINE SPEED SENSOR...545
BOOST PRESSURE...546
GOVERNOR MOTOR LEVER STROKE...547
WORK, SWING, AND TRAVEL CIRCUIT...548
TVC VALVE OUTPUT PRESSURE...551
LS VALVE OUTPUT AND DIFFERENTIAL PRESSURE...553
CONTROL CIRCUIT OIL PRESSURE...556
SOLENOID VALVE OUTPUT PRESSURE...557
PPC VALVE OUTPUT PRESSURE AND SHUTTLE VALVE...560
WORK EQUIPMENT, SWING PPC VALVE...562
TRAVEL DEVIATION...563
LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...564
MEASURING OIL LEAKAGE...566
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...569
TESTING CLEARANCE OF SWING CIRCLE BEARING...570
WEAR OF SPROCKET...571
TRACK SHOE TENSION...572
BLEEDING AIR...573
TROUBLESHOOTING GENERAL...576
POINTS TO REMEMBER WHEN TROUBLESHOOTING...578
SEQUENCE OF EVENTS IN TROUBLESHOOTING...580
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...581
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT...581
HANDLING CONTROL BOX...586
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...587
CHECKS BEFORE TROUBLESHOOTING...589
JUDGEMENT OF POWER TRAIN...590
PRECAUTIONS WHEN TROUBLESHOOTING...591
SAFETY...591
METHODS FOR TROUBLESHOOTING...591
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING...593
PREVENTING RECURRENCE OF TROUBLE...594
HYDRAULIC EQUIPMENT...594
OIL CHECKS...594
CLEANING FRAGMENTS OF DAMAGED PARTS...594
METHOD OF USING TROUBLESHOOTING CHARTS...595
CATEGORY OF TROUBLESHOOTING CODE NUMBER...595
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE...595
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...597
METHOD OF USING ENGINE RELATED CHARTS...599
TROUBLESHOOTING...604
CONNECTOR TYPES AND MOUNTING LOCATIONS...605
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...608
CONTROL MECHANISM FOR ELECTRICAL SYSTEM...618
MACHINE CONTROL FUNCTIONS...618
MONITORING PANEL...619
DISPLAY ON MACHINE MONITOR...619
RECORDING OF SERVICE CODES AND USER CODE DISPLAY FUNCTION...619
MACHINE DATA MONITORING FUNCTION...621
METHOD OF DISPLAYING MONITORING CODE...621
TABLE OF MACHINE MONITORING CODES...622
BIT PATTERN CHART...623
GOVERNOR MOTOR ADJUSTMENT MODE...625
TIME ADJUSTMENT MODE...625
WORKING MODE DEFAULT SETTING MODE...626
METHOD OF USING JUDGEMENT TABLE...627
WHEN USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYSTEM] AND ENGINE REL....627
WHEN USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYSTEM] AND HYDRAULIC ....628
METHOD OF USING TROUBLESHOOTING CHARTS...629
CATEGORY OF TROUBLESHOOTING CODE NUMBER...629
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE...629
TROUBLESHOOTING CODE NUMBER AND PROBLEM...629
DISTINGUISHING CONDITIONS...629
METHOD OF FOLLOWING TROUBLESHOOTING CHART...629
GENERAL PRECAUTIONS...629
DETAILS OF TROUBLESHOOTING AND PROCEDURE...632
PROCEDURE FOR CHECKING MONITOR PANEL OUTPUT SIGNAL...634
CHECKING INPUT SIGNAL OF GOVERNOR, PUMP CONTROLLER...635
SERVICE CODE TABLE...637
TROUBLSHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N-MODE)...638
N-1 [E218] Communication abnormality...639
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER, GOVERNOR CONTROL SYSTEM (E-MODE)...642
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM...643
ACTIONS TAKEN...644
JUDGEMENT TABLE...646
ELECTRICAL CIRCUIT DIAGRAM FOR MODE SYSTEM...647
E-1 Abnormality in governor, pump controller power source, controller LED is OFF...648
E-2 [E308] Abnormality in fuel control dial input value is displayed...649
E-3 [E317] Abnormality, disconnection in motor drive system is displayed...650
E-4 [E318] Abnormality, short circuit in motor drive system is displayed...651
E-5 [E306] Abnormality in feedback potentiometer system is displayed...652
E-6 [E315] Abnormality, short circuit in battery relay output system is displayed...653
E-7 [E316] Abnormality, step out in motor displayed...654
E-8 Engine does not start...655
E-9 Engine does not start...658
E-10 Lack of output, engine high idle speed too low...659
E-11 Engine does not stop...660
E-12 Faulty operation of battery relay system, engine does not stop...661
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)...664
METHOD OF USING ENGINE RELATED CHARTS...665
S-1 Starting performance is poor (Starting always take time)...670
S-2 Engine does not start...671
S-3 Engine does not pick up smoothly (Follow-up is poor)...674
S-4 Engine stops during operation...675
S-5 Engine does not run smoothly (Hunting)...676
S-6 Engine lacks output (No power)...677
S-7 Exhaust gas is black (Incomplete Combustion)...678
S-8 Oil consumption is excessive (or exhaust gas is blue)...679
S-9 Oil becomes contaminated quickly...680
S-10 Fuel consumption is excessive...681
S-11 Oil in coolant, or coolant spurts back, or coolant level goes down...682
S-12 Oil pressure lamp lights up (Drop in oil pressure)...683
S-13 Oil level rises...684
S-14 Coolant Temperature becomes too high (Overheating)...685
S-15 Abnormal noise is made...686
S-16 Vibration is excessive...687
TROUBLESHOOTING OF GOVERNOR PUMP CONTROLLER, PUMP CONTROL SYSTEM (C-MODE)...688
POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM...689
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...690
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS...694
ELECTRIC CIRCUIT DIAGRAM FOR C MODE...695
C-1 Abnormality in controller power source system, controller LED is OFF...697
C-2 [E232] Short circuit in front pump TVC solenoid system is displayed...698
C-3 [E233] Disconnection in front pump TVC solenoid system is displayed...699
C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed...700
C-5 [E237] Disconnection in rear pump TVC solenoid system is displayed...701
C-6 [E207] Short circuit in LS select solenoid system is displayed...702
C-7 [E208] Disconnection in active mode, boom, solenoid system is displayed...704
C-8 [E203] Short circuit in swing brake solenoid system is displayed...705
C-9 [E213] Disconnection in swing brake solenoid system is displayed...706
C-10 [E204] Short circuit in pump merge divider solenoid system is displayed...707
C-11 [E214] Disconnection in pump merge divider solenoid system is displayed...708
C-12 [E206] Short circuit in travel speed solenoid system is displayed...709
C-13 [E216] Disconnection in travel speed selector solenoid system is displayed...710
C-14 [E217] Short circuit in active mode, swing, solenoid system is displayed...711
C-15 [E235] Disconnection in active mode, swing, solenoid system is displayed...712
C16 [E217] Model selection input error is displayed...713
C-17 [E222] Short circuit in LS-EPC solenoid system is displayed...715
C-18 [E224] Disconnection in LS-EPC solenoid system is displayed...716
C-19 [E224] Abnormality in front pump pressure sensor system is displayed...717
C-20 [E225] Abnormality in rear pump pressure sensor system is displayed...718
C-21 [E226] Abnormality in i pressure sensor power source system is displayed...719
C-22 [E227] Abnormality in engine speed sensor system is displayed...720
C-23 [E225] Abnormality in machine push up solenoid system, no service code displayed...721
a) If solenoid is not actuated, turned on, when machine push up switch is set to low pressure setting...721
b) If solenoid is not canceled, turned off, when machine push up switch is set to high pressure setting...722
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER, INPUT SIGNAL SYSTEM (F-MODE)...724
ELECTRIC CIRCUIT DIAGRAM FOR F MODE...726
F-1 Bit pattern 20-[1] Swing oil pressure switch does not light up...727
F-2 Bit pattern 20-[2] Travel oil pressure switch does not light up...728
F-3 Bit pattern 20-[3] Boom LOWER oil pressure switch does not light up...729
F-4 Bit pattern 20-[4] Boom RAISE oil pressure switch does not light up...730
F-5 Bit pattern 20-[5] Arm IN oil pressure switch does not light up...731
F-6 Bit pattern 20-[6] Arm OUT oil pressure switch does not light up...732
F-7 Bit pattern 21-[1] Bucket CURL oil pressure switch does not light up...733
F-8 Bit pattern 21-[2] Bucket DUMP oil pressure switch does not light up...734
F-9 Bit pattern 21-[3] Swing lock oil pressure switch does not light up...735
F-10 Bit pattern 22-[5] Mode connection does not light up...736
F-11 Bit pattern 22-[6] Left knob switch does not light up...737
TROUBLESHOOTING OF MACHINE MECHANICAL MODE (H-MODE)...738
PUMP MERGE DIVIDER LOGIC...739
SOLENOID ACTUATION TABLE...739
TABLE OF FAILURE MODES AND CAUSES...740
H-1 Speeds of all work equipment swing, travel are slow or lack power...742
H-2 There is excessive drop in engine speed, or engine stalls...743
H-3 No work equipment, travel, swing movement...743
H-4 Abnormal noise generated around pump...744
H-5 Auto decel does not work when PPC shuttle valve is cause...744
H-6 Fine control ability is poor or response is poor...744
H-7 Boom is slow or lacks power...745
H-8 Arm is slow or lacks power...746
H-9 Bucket is slow or lacks power...747
H-10 Work Equipment; Boom, Arm, Bucket, Does Not Move, But Travel and Swing Are Normal...748
H-11 Excessive hydraulic drift, boom, arm, bucket ...748
1) Excessive hydraulic drift of boom...748
2) Excessive hydraulic drift of arm or bucket...748
H-12 Excessive time lag, engine at low idling...749
H-13 Other equipment moves when single circuit is relieved...749
H-14 In L/O, F3/O modes, work equipment speed is faster than specified speed...750
H-15 Malfunction of machine push up function...750
H-16 In compound operations, work equipment with larger load is slow...750
H-17 In swing plus boom RAISE, boom RAISE is slow...751
H-18 In swing plus arm, arm is slow...751
H-19 In swing plus travel, travel speed drops excessively...751
H-20 Travel deviation...752
H-21 Travel speed is slow...754
H-22 Steering does not turn easily or lacks power...755
H-23 Travel speed does not switch or is faster than specified speed...756
H-24 Travel does not move, one side only...756
H-25 Does not swing...757
H-26 Travel speed is slow...758
H-27 Excessive overrun when stopping swing...759
H-28 Excessive shock when stopping swing, one direction only...760
H-29 Excessive abnormal noise when stopping swing...760
H-30 Excessive hydraulic drift of swing...761
H-31 Swing speed is faster than specified swing speed...761
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M-MODE)...762
ACTIONS TAKEN BY MONITOR PANEL...764
ELECTRIC CIRCUIT DIAGRAM FOR M MODE...765
M-1 [E101] Abnormality in error data is displayed...766
[E102] Error in clock data is displayed...766
M-2 [E103] Short circuit in buzzer output or 24V wiring harness contact with buzzer harness is displayed...767
M-3 [E104] Air cleaner restriction detected is displayed...768
M-4 [E106] Drop in engine oil Hi pressure detected is displayed...768
M-5 [E108] Engine coolant temperature 105 C detected is displayed...768
M-6 When start switch is turned ON, no lamps on monitor panel light up for three seconds...769
M-7 When start switch is turned ON, monitor panel lamps all stay illuminated and do not go out...771
M-8 When start switch is turned ON, items illuminated on monitor panel are different from actual machine...771
M-9 When start switch is turned ON, engine stopped, basic check items flash...772
M-10 Preheating is not used, but on monitor panel lights up...775
M-11 When start switch is turned ON and engine is started, basic check items flash...776
M-12 When start switch is turned ON, engine speed, caution items, emergency items flash. Battery, engine oil pressure lamps d...778
M-13 When start switch is turned ON and engine is started, caution items, emergency items flash, when there is no abnormality...780
M-14 When start switch is turned ON, engine stopped, buzzer does not sound for one second, Caution ite....783
M-15 No abnormality is displayed on monitor panel but buzzer sounds...784
M-16 Night light on monitor panel does not light up, liquid crystal display is normal...785
M-17 Coolant temperature gauge does not rise...786
M-18 Coolant temperature gauge does not give any display, no gauge lamps light up during operation...787
M-19 Fuel level gauge always displays FULL...788
M-20 Fuel level gauge does not give display...789
M-21 Swing lock switch is turned ON, but on monitor panel does not light...790
M-22 Swing prolix switch is turned ON, but on monitor panel does not flash...791
M-23 Service meter does not advance while engine is running...792
M-24 When start switch is at OFF and time switch is pressed, time and service meter are not displayed...792
M-25 Faulty fuel level sensor system...793
M-26 Faulty coolant temperature sensor system...794
M-27 Faulty engine oil level sensor system...795
M-28 Faulty coolant level sensor system...796
M-29 Faulty hydraulic oil level sensor system...797
M-30 [E112, E113] Wiper does not work or switch is not being used, but wiper is actuated...798
M-31 [E114] Wiper does not work or switch is not being used, but washer motor is not actuated...802
30 DISASSEMBLY AND ASSEMBLY...804
METHOD OF USING MANUAL...805
SPECIAL TOOL LIST...810
SKETCHES OF SPECIAL TOOLS...815
STARTING MOTOR...823
REMOVAL...823
INSTALLATION...823
ALTERNATOR...824
REMOVAL...824
INSTALLATION...824
ENGINE OIL COOLER...825
REMOVAL...825
INSTALLATION...825
FUEL INJECTION PUMP...826
REMOVAL...826
INSTALLATION...827
WATER PUMP...828
REMOVAL...828
INSTALLATION...828
NOZZLE HOLDER...829
REMOVAL...829
INSTALLATION...829
TURBOCHARGER...830
REMOVAL...830
INSTALLATION...830
THERMOSTAT...831
REMOVAL...831
INSTALLATION...831
FRONT ENGINE SEAL...832
REMOVAL...832
INSTALLATION...832
REAR ENGINE SEAL...833
REMOVAL...833
INSTALLATION...834
CYLINDER HEAD...836
REMOVAL...836
INSTALLATION...840
GOVERNOR MOTOR...843
REMOVAL...843
INSTALLATION...843
AFTERCOOLER CORE...844
REMOVAL...844
INSTALLATION...844
OIL COOLER...845
REMOVAL...845
INSTALLATION...846
RADIATOR, OIL COOLER...847
REMOVAL...847
INSTALLATION...849
ENGINE, MAIN PUMP...850
REMOVAL...850
INSTALLATION...854
DAMPER...856
REMOVAL...856
INSTALLATION...856
FUEL TANK...857
REMOVAL...857
INSTALLATION...857
CENTER SWIVEL JOINT...858
REMOVAL...858
INSTALLATION...858
DISASSEMBLY...859
ASSEMBLY...859
FINAL DRIVE...860
REMOVAL...860
INSTALLATION...860
DISASSEMBLY...861
ASSEMBLY...865
TRAVEL MOTOR...871
DISASSEMBLY...871
ASSEMBLY...875
SPROCKET...884
REMOVAL...884
INSTALLATION...884
SWING MOTOR...885
REMOVAL...885
INSTALLATION...885
DISASSEMBLY...886
ASSEMBLY...888
SWING MACHINERY...895
REMOVAL...895
INSTALLATION...895
DISASSEMBLY...896
ASSEMBLY...899
REVOLVING FRAME...904
REMOVAL...904
INSTALLATION...905
SWING CIRCLE...906
REMOVAL...906
INSTALLATION...906
IDLER AND RECOIL SPRING...907
REMOVAL...907
INSTALLATION...907
IDLER...908
DISASSEMBLY...908
ASSEMBLY...909
RECOIL SPRING...912
DISASSEMBLY...912
ASSEMBLY...913
TRACK ROLLER...914
REMOVAL...914
INSTALLATION...914
DISASSEMBLY...915
ASSEMBLY...916
CARRIER ROLLER...919
REMOVAL...919
INSTALLATION...919
DISASSEMBLY...920
ASSEMBLY...921
TRACK CHAIN...924
REMOVAL...924
INSTALLATION...924
HYDRAULIC TANK...925
REMOVAL...925
INSTALLATION...926
MAIN PUMP...927
REMOVAL...927
INSTALLATION...928
DISASSEMBLY...929
PUMP ASSEMBLY...929
FRONT PUMP...929
REAR PUMP...934
ASSEMBLY...937
FRONT PUMP...937
REAR PUMP...944
MAIN PUMP OIL SEAL...955
REMOVAL...955
INSTALLATION...955
CONTROL VALVE...956
REMOVAL...956
INSTALLATION...958
DISASSEMBLY...959
(1/3)...959
(2/3)...960
(3/3)...961
ASSEMBLY...964
(1/3)...964
(2/3)...965
(3/3)...966
PUMP MERGE DIVIDER VALVE...970
DISASSEMBLY...970
ASSEMBLY...970
PRESSURE COMPENSATION VALVE...971
DISASSEMBLY...971
ASSEMBLY...971
FRONT PUMP SERVO VALVE...972
REMOVAL...972
INSTALLATION...972
REAR PUMP SERVO VALVE...973
REMOVAL...973
INSTALLATION...973
LS-EPC SOLENOID VALVE...974
REMOVAL...974
INSTALLATION...974
SOLENOID VALVE...975
REMOVAL...975
INSTALLATION...975
WORK EQUIPMENT PPC VALVE...976
REMOVAL...976
INSTALLATION...976
DISASSEMBLY...977
ASSEMBLY...977
TRAVEL PPC VALVE...978
REMOVAL...978
INSTALLATION...978
DISASSEMBLY...979
ASSEMBLY...979
PPC SHUTTLE VALVE...980
REMOVAL...980
INSTALLATION...981
DISASSEMBLY...981
ASSEMBLY...982
BOOM LOCK VALVE...983
REMOVAL...983
INSTALLATION...983
DISASSEMBLY...984
ASSEMBLY...984
BOOM CYLINDER...985
REMOVAL...985
INSTALLATION...985
ARM CYLINDER...987
REMOVAL...987
INSTALLATION...987
BUCKET CYLINDER...988
REMOVAL...988
INSTALLATION...988
HYDRAULIC CYLINDER...990
THREADED STYLE PISTON...990
DISASSEMBLY...990
ASSEMBLY...992
WORK EQUIPMENT...996
REMOVAL...996
INSTALLATION...997
BUCKET...998
REMOVAL...998
INSTALLATION...999
ARM...1000
REMOVAL...1000
INSTALLATION...1001
BUCKET AND ARM...1002
REMOVAL...1002
INSTALLATION...1003
BOOM...1004
REMOVAL...1004
INSTALLATION...1005
OPERATOR’S CAB...1006
REMOVAL...1006
INSTALLATION...1007
COUNTERWEIGHT...1008
REMOVAL...1008
INSTALLATION...1008
COMPRESSOR...1009
REMOVAL...1009
INSTALLATION...1009
CONDENSER...1010
REMOVAL...1010
INSTALLATION...1010
RECEIVER TANK...1011
REMOVAL...1011
INSTALLATION...1011
AIR CONDITIONER UNIT...1012
REMOVAL...1012
INSTALLATION...1013
GOVERNOR, PUMP CONTROLLER...1014
REMOVAL...1014
INSTALLATION...1014
MONITOR PANEL...1015
REMOVAL...1015
INSTALLATION...1015
CONTROL STAND CASE...1016
REMOVAL...1016
TRAY...1016
BOOT...1016
UPPER CASE...1017
INSTALLATION...1017
40 MAINTENANCE STANDARD...1018
ENGINE MOUNT...1019
RADIATOR AND OIL COOLER MOUNT...1020
SWING MACHINERY...1024
SWING CIRCLE...1025
FINAL DRIVE...1026
TRACK FRAME AND RECOIL SPRING...1027
IDLER...1031
CARRIER ROLLER...1033
TRACK ROLLER...1034
TRACK SHOE...1035
TRACK SHOE...1037
HYDRAULIC PUMP...1038
CONTROL VALVE...1039
SELF REDUCING PRESSURE VALVE...1046
SUCTION SAFETY VALVE...1047
SWING MOTOR...1048
TRAVEL MOTOR...1049
WORK EQUIPMENT • SWING PPC VALVE...1050
TRAVEL PPC VALVE...1051
SERVICE PPC VALVE...1052
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE...1053
LS-EPC VALVE...1054
SOLENOID VALVE...1055
CENTER SWIVEL JOINT...1056
BOOM HOLDING VALVE...1057
HYDRAULIC CYLINDER...1059
BOOM, BUCKET CYLINDER - THREADED PISTON...1059
ARM CYLINDER - THREADED PISTON...1059
WORK EQUIPMENT...1061
DIMENSIONS OF WORK EQUIPMENT...1063
BUCKET...1065
90 OTHERS...1068
Foldout 20-203 Connector types and mounting location...1070
Foldout 20-229 Details of troubleshooting and troubleshooting procedures...1072
Foldout 20-353 Actions taken by controller when abnormality occurs and problems on machine...1074
Foldout 20-354 Action taken by controller when abnormality occurs and problems on machine...1076
Foldout 20-355 Judgement table for governor pump controller and engine related parts...1078
Foldout 20-356 Electrical circuit diagram for E mode...1080
Foldout 20-365 E-8 Engine does not start...1082
Foldout 20-366 E-9a Engine speed is irregular...1084
Foldout 20-367 E-9b There is hunting...1086
Foldout 20-368 E-10 Lack of output, engine high idle speed is low...1088
Foldout 20-369 E-11 Engine does not stop...1090
Foldout 20-453 Actions taken by controller when abnormality occurs and problems on machine...1092
Foldout 20-454 Actions taken by controller when abnormality occurs and problemss...1094
Foldout 20-455 Actions taken by controller when abnormality occurs and problems on machine...1096
Foldout 20-456 Actions taken by controller when abnromality occurs and problems on machine...1098
Foldout 20-457 Judgement table for governor, pump controller (pump control system) and hydraulic related parts...1100
Foldout 20-458 Electric circuit diagram for C mode...1102
Foldout 20-461 C-2 [E232] Short circuit in front pump TVC solenoid is displayed...1104
Foldout 20-462 C-3 [E233] Disconnection in front pump TVC solenoid system is displayed...1106
Foldout 20-463 C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed...1108
Foldout 20-464 C-5 [E237] Disconnection in rar pump TVC solenid system is displayed...1110
Foldout 20-467 C-7 [E208] Disconnection in active mode, boom, solenoid system is displayed...1112
Foldout 20-468 C-8 [E203] Short circuit in swing brake solenoid system is displayed...1114
Foldout 20-469 C-9 [E213] Disconnection in swing brake solenoid system is displayed...1116
Foldout 20-471 C-11 [E214] Disconnection in pump merge divider solenoid system is displayed...1118
Foldout 20-473 C-13 [E216] Disconnection in travel speed selector solenoid system is displayed...1120
Foldout 20-475 C-15 [E235] Disconnection in active mode, swlin solenoid system is displayed...1122
Foldout 20-503 Electric circuit diagram for F mode...1124
Foldout 20-553 Table of failure modes and causes (1/2)...1126
Foldout 20-554 Table of fialure modes and causes (2/2)...1128
Foldout 20-555 H-1 Speed of all work equipment, swing, travel are slow or lack power...1130
Foldout 20-557 H-4 Abnormal noise generated around pump...1132
Foldout 20-557 H-5 Auto decel does not work when PPC shuttle valve is cause...1132
Foldout 20-557 H-6 Fine control ability is poor or response is poor...1132
Foldout 20-558 H-7 Boom is slow or lacks power...1134
Foldout 20-559 H-8 Arm is slow or lacks power...1136
Foldout 20-560 H-9 Bucket is slow or lacks power...1138
Foldout 20-567 H-21 Travel speed is slow...1140
Foldout 20-568 H-22 Steering does not turn easily or lacks power...1142
Foldout 20-571 H-26 Travel speed is slow...1144
Foldout 20-603 Actions taken by controller when abnormality occurs and problems on machine...1146
Foldout 20-604 Electric circuit diagram for M mode...1148
Foldout 20-637 M-30 Wiper does not work or switch is not being used, but wiper is actuated [include E112, E113]...1150
Foldout 20-638 M-30 (continued)...1152
Foldout 20-641 M-31 Wiper does not work or switch is not being used, but washer motor is actuated (include E114)...1154
Komatsu Hydraulic Excavators PC400LC-LM, PC400HD-LM Series Repair Service Manuals
