Komatsu PC400LC-8 - Service Manual / Repair Manual - Wiring Diagrams

KOMATSU PC400LC-8 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, for Komatsu PC400LC-8.
 

CONTENTS:

CEBM018803 - PC400LC-8 SN A88001-A88545
- CONTENTS
- REVISED PAGES
- SAFETY
- Safety Notice
- Important Safety Notice
- General Precautions
- Preparations For Work
- Precautions During Work
- GENERAL
- HOW TO READ THE SHOP MANUAL
- Volumes
- Distribution And Updating
- Filing Method
- Revised Edition Mark
- Revisions
- Symbols
- HOISTING INSTRUCTIONS
- Hoisting
- Wire Ropes
- PUSH PULL COUPLER
- Type 1
- Disconnection
- Connection
- Type 2
- Disconnection
- Connection
- Type 3
- Disconnection
- Connection
- EXPLANATION OF MAINTENANCE STANDARD TERMS
- STANDARD TIGHTENING TORQUE
- Bolts And Nuts
- Tightening Torque Of Hose Nuts
- Tightening Torque Of Split Flange Bolts
- Tightening Torque For Flared Nuts
- Tightening Torques For O-ring Boss Piping Joints
- Table Of Tightening Torques For O-ring Boss Plugs
- Torque Table For Hoses (Taper Seal Type And Face Seal Type)
- ELECTRIC WIRE CODE
- Classification By Thickness
- Classification By Color And Code
- How To Read Electric Wire Code
- CONVERSION TABLES
- Method Of Using The Conversion Table
- COATING MATERIALS
01 GENERAL
- SPECIFICATION DIMENSION DRAWINGS
- Dimensions
- Working Ranges
- SPECIFICATIONS
- WEIGHT TABLE
- FUEL, COOLANT AND LUBRICANTS
- Lubrication Chart
10 STRUCTURE, FUNCTION ANDMAINTENANCE 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
- Triple Grouser Shoe
- HYDRAULIC SYSTEM
- Hydraulic Piping Drawing
- Hydraulic Tank And Filter
- Hydraulic Pump
- LS Valve
- PC Valve
- LS(PC)-EPC Valve
- Variable Volume Valve
- Control Valve
- CLSS (Closed Center Load Sensing System)
- Functions And Operation By Valve
- Unload Valve
- LS Bypass Valve
- Pressure Compensation Valve
- Pressure Compensation Valve Inner Shuttle Valve
- Boom Regeneration Circuit
- Arm Regeneration Circuit
- Merge-Divider Valve
- LS Select Valve
- Self Pressure Reducing Valve
- Travel Junction Valve
- Travel PPC Shuttle Valve
- Boom Drift Preventive Valve
- Arm Drift Preventive Valve
- Quick Return Valve
- Lift Check Valve
- Main Relief Valve
- 2-Stage Safety-Suction Valve
- Variable Pressure Compensation Valve
- Attachment Circuit Selector Valve
- Holding Valve
- Valve Control
- PPC Valve
- Travel PPC Valve
- Service PPC Valve (With EPC Valve)
- Solenoid Valve
- PPC Accumulator
- Return Oil Filter
- Center Swivel Joint
- Travel Motor
- Brake Valve
- Swing Motor
- Reverse Prevention Valve
- Hydraulic Cylinder
- Boom Cylinder
- Arm Cylinder
- Bucket Cylinder
- WORK EQUIPMENT
- Work Equipment
- Dimensions Of Components
- Dimension Of Arm
- Dimension Of Bucket
- AIR CONDITIONER PIPING
- ELECTRICAL SYSTEM
- Engine Control
- Fuel Control Dial
- Engine Controller
- Sensors
- Rotation Sensor
- Oil Pressure Switch
- Ambient Pressure Sensor
- Boost Pressure Sensor
- Boost Temperature Sensor
- Coolant Temperature Sensor
- Hydraulic Oil Temperature Sensor
- EGR Valve Stroke Sensor
- Engine Oil Level Sensor
- ELECTRONIC CONTROL SYSTEM
- Engine And Pump Composite Control Function
- Pump And Valve Control
- 2-Stage Relief Function
- Power Maximizing And Machine Push-up
- Auto-Deceleration
- Auto-Warm-Up And Overheat Prevention
- Swing Control
- Travel Control
- Attachment Flow Control And Circuit Selector
- System Component Parts
- PPC Oil Pressure Switch
- Oil Pressure Sensor
- Pump Pressure Sensor (High Pressure)
- Pump Controller
- MONITOR SYSTEM
- Machine Monitor
- Monitor Control, Display Portion
- Monitor Items And Display
- Switches
- Komtrax Logic
- Sensors
- KOMTRAX TERMINAL SYSTEM
- Komtrax Communication Modem - TH300
20 STANDARD VALUE TABLES
- STANDARD VALUE TABLES
- Engine Related
- Chassis Related
30 TESTING AND ADJUSTING
- SERVICE TOOLS
- Sketches Of Special Tools
- ENGINE
- Engine Speed
- Air Boost Pressure
- Exhaust Temperature
- Exhaust Gas Color
- Valve Clearance
- Compression Pressure
- Blow-By Pressure
- Engine Oil Pressure
- EGR Valve Drive Pressure
- Handling Fuel System Parts
- Releasing Residual Pressure From Fuel System
- Fuel Pressure
- Cylinder Cut-Out Operation
- No Injection Cranking Operation
- Fuel Return Rate And Leakage
- Bleeding Air From Fuel Circuit
- Fuel Circuit, Checking For Leakage
- FAN BELT AND ALTERNATOR BELT TENSION
- AIR CONDITIONER COMPRESSOR BELT TENSION
- SWING CIRCLE BEARING CLEARANCE
- TRACK SHOE TENSION
- OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
- CONTROL CIRCUIT - BASIC PRESSURE
- PUMP PC CONTROL CIRCUIT
- PUMP LS CONTROL CIRCUIT
- SOLENOID VALVE - OUTPUT PRESSURE
- PPC VALVE - OUTPUT PRESSURE
- WORK EQUIPMENT PPC VALVE AND SWING PPC VALVE - PLAY ADJUSTMENT
- WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE
- HYDRAULIC CIRCUIT - RELEASING REMAINING PRESSURE
- Oil Leakage Measurement
- BLEEDING AIR FROM VARIOUS PARTS
- MACHINE MONITOR - SPECIAL FUNCTIONS
- Ordinary Functions And Special Functions Of Machine Monitor
- Operator Mode (Outline)
- Display Of Komatsu Logo
- Display Of Inputting Password
- Display Of Check Of Breaker Mode
- Display Of Check Before Starting
- Display Of Warning After Check Before Starting
- Display Of Ending Of Maintenance Interval
- Display Of Check Of Working Mode And Travel Speed
- Display Of Ordinary Screen
- Display Of End Screen
- Selection Of Auto-Deceleration
- Selection Of Working Mode
- Selection Of Travel Speed
- Operation To Stop Alarm Buzzer
- Operation Of Windshield Wiper
- Operation Of Window Washer
- Operation Of Air Conditioner/Heater
- Operation To Display Camera Mode (If Camera Is Installed)
- Operation To Display Clock And Service Meter
- Check Of Maintenance Information
- Setting And Display Of User Mode
- KOMTRAX Message
- Display Of Energy-Saving Guidance
- Display Of Caution Monitor
- Display Of Automatic Judgment Of Breaker
- Display Of User Code And Failure Code
- Function Of Checking Display Of LCD (Liquid Crystal Display)
- Function Of Checking Service Meter
- Function Of Changing Attachment/Maintenance Password
- Service Mode
- Monitoring
- Abnormality Record (Mechanical Systems)
- Abnormality Record (Electrical Systems)
- Abnormality Record (Air-Conditioning System/Heater System)
- Maintenance Record
- Maintenance Mode Change
- Phone Number Entry
- Default (Key-On Mode)
- Default (Unit)
- Default (With/Without Attachment)
- Default (Attachment/Maintenance Password)
- Default (Camera)
- Default (ECO Display)
- Default (Breaker Detect)
- Adjustment (Pump Absorption Torque (F))
- Adjustment (Pump Absorption Torque (R))
- Adjustment (Low Speed)
- Adjustment (Attachment Flow Adjustment)
- Determining A Defective Cylinder
- Cylinder Cut-Out
- No Injection
- Fuel Consumption
- KOMTRAX Settings (Terminal Status)
- Long Distance Transport Mode
- KOMTRAX Settings (GPS & Communication Status)
- KOMTRAX Setting (Modem S/N: TH300)
- Display Of KOMTRAX Message
- HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
- PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM
- DIODE INSPECTION PROCEDURES
- PM CLINIC SERVICE
40 TROUBLESHOOTING
- FAILURE CODES TABLE
- FUSE LOCATIONS
- Connection Table Of Fuse Box
- Location Of Fuse Box And Fuse Numbers
- GENERAL INFORMATION
- Points To Remember When Troubleshooting
- Sequence Of Events In Troubleshooting
- Handling Electric Equipment And Hydraulic Components
- Connectors Newly Used For Tier 3 Engines
- Checks Before Troubleshooting
- Classification And Troubleshooting Steps
- Classification Of Troubleshooting
- Information In Troubleshooting Table
- Possible Problems And Troubleshooting No.
- Connection Table For Connector Pin Numbers
- T-adapter Box And T-adapter Table
- FAILURE CODE (DISPLAY OF CODE)
- 989L00 - Engine Controller Lock Caution 1
- 989M00 - Engine Controller Lock Caution 2
- 989N00 - Engine Controller Lock Caution 3
- AA10NX - Air Cleaner Clogging
- AB00KE - Charge Voltage Low
- B@BAZG - Engine Oil Pressure Low
- B@BAZK - Engine Oil Level Low
- B@BCNS - Engine Coolant Overheat
- B@BCZK - Engine Coolant Level Low
- B@HANS - Hydraulic Oil Overheat
- CA111 - EMC Critical Internal Failure
- CA115 - Engine Ne And Bkup Speed Sensor Error
- CA122 - Charge Air Pressure Sensor High Error
- CA123 - Charge Air Pressure Sensor Low Error
- CA131 - Throttle Sensor High Error
- CA132 - Throttle Sensor Low Error
- CA135 - Engine Oil Pressure Sensor High Error
- CA141 - Engine Oil Pressure Sensor Low Error
- CA144 - Coolant Temperature Sensor High Error
- CA145 - Coolant Temperature Sensor Low Error
- CA153 - Charge Air Temperature Sensor High Error
- CA154 - Charge Air Temperature Sensor Low Error
- CA187 - Sensor Power Supply 2 Volt Low Error
- CA221 - Ambient Pressure Sensor High Error
- CA222 - Ambient Pressure Sensor Low Error
- CA227 - Sensor Supply 2 Volt High Error
- CA234 - Engine Overspeed
- CA238 - NE Speed Sensor Supply Voltage Error
- CA263 - Fuel Temperature Sensor High Error
- CA265 - Fuel Temperature Sensor Low Error
- CA271 - IMV/PCV1 Short Error
- CA272 - IMV/PCV1 Open Error
- CA273 - PCV2 Short Error
- CA274 - PCV2 Open Error
- CA322 - Injector #1 Open/short Error
- CA323 - Injector #5 Open/short Error
- CA324 - Injector #3 Open/short Error
- CA325 - Injector #6 Open/short Error
- CA331 - Injector #2 Open/short Error
- CA332 - Injector #4 Open/short Error
- CA342 - Calibration Code Incompatibility
- CA351 - Injectors Drive Circuit Error
- CA352 - Sensor Supply 1 Volt Low Error
- CA386 - Sensor Supply 1 Volt High Error
- CA441 - Battery Voltage Low Error
- CA442 - Battery Voltage High Error
- CA449 - Rail Pressure Very High Error
- CA451 - Rail Pressure Sensor High Error
- CA452 - Rail Pressure Sensor Low Error
- CA553 - Rail Pressure High Error
- CA554 - Rail Pressure Sensor In Range Error
- CA559 - Rail Pressure Low Error
- CA689 - Engine Ne Speed Sensor Error
- CA731 - Engine Bkup Speed Sensor Phase Error
- CA757 - All Persistent Data Lost Error
- CA778 - Engine Bkup Speed Sensor Error
- CA1228 - EGR Valve Servo Error 1
- CA1625 - EGR Valve Servo Error 2
- CA1633 - KOMNET Datalink Timeout Error
- CA2185 - Throttle Sensor Supply Volt High Error
- CA2186 - Throttle Sensor Supply Volt Low Error
- CA2249 - Rail Pressure Very Low Error
- CA2272 - EGR Valve Lift Sensor Low Error
- CA2351 - EGR Valve Solenoid Operation Short Circuit
- CA2555 - Grid Htr Relay Volt High Error
- CA2556 - Grid Htr Relay Volt Low Error
- D110KB - Battery Relay Drive Short Circuit
- D19JKZ - Personal Code Relay Abnormality
- D862KA - GPS Antenna Discon
- DA22KK - Pump Solenoid Power Low Error
- DA25KP - 5 V Sensor Power Supply Output 1 Abnormality
- DA29KQ - Model Selection Abnormality
- DA2RMC - CAN Discon (Pump Con Detected)
- DAF8KB - Short circuit in camera power supply
- DAFGMC - GPS Module Error
- DAFRMC - CAN Discon (Monitor Detected)
- DGH2KB - Hyd Oil Sensor Short
- DHPAMA - F Pump Pressure Sensor Abnormality
- DHPBMA - R Pump Pressure Sensor Abnormality
- DHS3MA - Arm Curl In PPC Sensor Abnormality
- DHS4MA - Bucket Curl PPC Pressure Sensor Abnormality
- DHX1MA - Overload Sensor Abnormality (Analog)
- DW43KA - Travel Speed Solenoid Disconnection
- DW43KB - Travel Speed Solenoid Short Circuit
- DW45KA - Swing Brake Solenoid Disconnection
- DW45KB - Swing Brake Solenoid Short Circuit
- DW91KA - Travel Junction Solenoid Disconnection
- DW91KB - Travel Junction Solenoid Short Circuit
- DWA2KA - Attachment Sol Open Circuit
- DWA2KB - Attachment Sol Short Circuit
- DWJ0KA - Merge-divider Solenoid Disconnection
- DWJ0KB - Merge-divider Solenoid Short Circuit
- DWK0KA - 2-stage Relief Solenoid Disconnection
- DWK0KB - 2-stage Relief Solenoid Short Circuit
- DXA0KA - PC-EPC Solenoid Disconnection
- DXA0KB - PC-EPC Solenoid Short Circuit
- DXE0KA - LS-EPC Solenoid Disconnection
- DXE0KB - LS-EPC Solenoid Short Circuit
- DXE4KA - Service Current EPC Disconnection
- DXE4KB - Service Current EPC Short Circuit
- DY20KA - Wiper Working Abnormality
- DY20MA - Wiper Parking Abnormality
- DY2CKA - Washer Drive Open Circuit
- DY2CKB - Washer Drive Short Circuit
- DY2DKB - Wiper Drive (Fwd) Short Circuit
- DY2EKB - Wiper Drive (Rev) Short Circuit
- E-MODE (ELECTRICAL SYSTEM)
- 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 System 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 Indicate Normally
- E-14 Swing Lock Monitor Does Not Indicate Normally
- E-15 When Monitor Switch Is Operated, Monitor Displays Nothing
- E-16 Windshield Wiper And Window Washer Do 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 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
- H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)
- 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 Individual Operation
- H-11 Work Equipment Has A Bit Too Fast Hydraulic Drift
- H-12 Work Equipment Has Long 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 In Swing + Boom Raise Operation, Boom Moves Slowly
- H-18 In Swing + Travel Operation, Travel Speed Drops Sharply
- H-19 Machine Swerves In Travel
- H-20 Machine Travels Slowly
- H-21 Machine Cannot Be Easily Steered Or Lacks Power
- H-22 Travel Speed Does Not Shift, Or It Is Too Slow Or Fast
- H-23 Travel System Does Not Turn (On One Side Only)
- H-24 Machine Does Not Swing
- H-25 Swing Acceleration Is Poor, Or Swing Speed Is Slow
- H-26 Excessive Overrun When Stopping Swing
- H-27 There Is Big Shock When Stopping Swing
- H-28 Large Sound Is Made When Upper Structure Stops Swinging
- H-29 Swing Hydraulic Drift Is Too Big
- H-30 Attachment Circuit Is Not Changed
- H-31 Oil Flow In Attachment Circuit Cannot Be Controlled
50 DISASSEMBLY AND ASSEMBLY
- HOW TO READ THIS MANUAL
- SPECIAL TOOLS LIST
- SKETCHES OF SPECIAL TOOLS
- CONNECTOR REPAIR PROCEDURES
- Contact Terminal Removal (HD30 Type)
- Striping Insulation
- Crimping Contact Terminal (HD30 Type)
- Insertion Of Contact Terminal (HD30 Type)
- Contact Terminal Removal (DT Type)
- Striping Insulation
- Crimping Contact Terminal (DT Type)
- Insertion Of Contact Terminal (DT Type)
- ENGINE COMPONENTS
- Fuel Supply Pump
- Removal
- Installation
- Fuel Injector
- Removal
- Installation
- Engine Front Seal
- Removal
- Installation
- Engine Rear Seal
- Removal
- Installation
- Cylinder Head
- Removal
- Installation
- Oil Pan Gasket
- RADIATOR
- Removal
- Installation
- HYDRAULIC OIL COOLER
- Removal
- Installation
- AFTERCOOLER
- Removal
- Installation
- ENGINE AND HYDRAULIC OIL PUMP
- Removal
- Installation
- DRIVE ASSEMBLY
- Removal
- Installation
- Disassembly
- Assembly
- SWING MOTOR AND SWING MACHINERY
- Removal
- Installation
- Disassembly
- Assembly
- SWING CIRCLE
- Removal
- Installation
- CARRIER ROLLER
- Assembly
- TRACK ROLLER
- Assembly
- IDLER
- Disassembly
- ASSEMBLY
- RECOIL SPRING
- Disassembly
- Assembly
- SPROCKET
- Removal
- Installation
- TRACK SHOE
- Expansion Of Track Shoe
- Installation Of Track Shoe
- REVOLVING FRAME
- Removal
- Installation
- COUNTERWEIGHT
- Removal
- Installation
- COUNTERWEIGHT REMOVER
- Removing
- Installing
- CENTER SWIVEL JOINT
- Removal
- Installation
- Disassembly
- Assembly
- HYDRAULIC TANK
- Removal
- Installation
- CONTROL VALVE
- Removal
- Installation
- Disassembly
- Assembly
- HYDRAULIC PUMP
- Removal
- Installation
- HYDRAULIC PUMP INPUT SHAFT OIL SEAL
- Removal
- Installation
- WORK EQUIPMENT PPC VALVE
- Disassembly
- Assembly
- TRAVEL PPC VALVE
- Disassembly
- Assembly
- HYDRAULIC CYLINDER
- Disassembly
- Assembly
- WORK EQUIPMENT
- Removal
- Installation
- CAB
- Removal
- Installation
- Cab Glass (Stuck Glass)
- Removal
- Installation
- Front Window
- Removal
- Installation
- Floor Frame
- Removal
- Installation
- ELECTRICAL SYSTEMS
- Air Conditioner Unit
- Removal
- Installation
- KOMTRAX Communication Modem
- Removal
- Installation
- Monitor
- Removal
- Installation
- Pump Controller
- Removal
- Installation
- Engine Controller
- Removal
- Installation
90 DIAGRAMS AND DRAWINGS
- Hydraulic circuit diagram
- Electrical circuit diagram (1/5)
- Electrical circuit diagram (2/5)
- Electrical circuit diagram (3/5)
- Electrical circuit diagram (4/5)
- Electrical circuit diagram (5/5)
- Connector list and stereogram