HYDRAULIC EXCAVATOR PC400-6 CUSTOM PC400LC-6 CUSTOM Shop Manual

COVER
CONTENTS
01 GENERAL
SPECIFICATION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE AND FUNCTION
PARTS RELATED TO ENGINE
RADIATOR, OIL COOLER
POWER TRAIN
FINAL DRIVE
SWING CIRCLE
SWING MACHINERY
TRACK FRAME, RECOIL SPRING
TRACK SHOE
HYDRAULIC PIPING DRAWING
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK, HYDRAULIC FILTER
HYDRAULIC PUMP
CONTROL VALVE
SUCTION SAFETY VALVE
CLSS
SWING MOTOR
CENTER SWIVEL JOINT
TRAVEL MOTOR
VALVE CONTROL
WORK EQUIPMENT, SWING PPC VALVE
TRAVEL PPC VALVE
SERVICE PPC VALVE
PPC SAFETY LOCK VALVE
PPC ACCUMULATOR
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
SOLENOID VALVE
BOOM HOLDING VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
ACTUAL ELECTRIC WIRING DIAGRAM
ELECTRIC CIRCUIT DIAGRAM
ENGINE CONTROL SYSTEM
ELECTRIC CONTROL SYSTEM
MACHINE MONITOR SYSTEM
SENSORS
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
ADJUSTING FUEL CONTROL LEVER
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE
TESTING SOLENOID VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
TESTING TRAVEL DEVIATION
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
MEASURING OIL LEAKAGE
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING AND ADJUSTING TRACK SHOE TENSION
BLEEDING AIR
TROUBLESHOOTING
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
STARTING MOTOR ASSEMBLY
ALTERNATOR ASSEMBLY
ENGINE OIL COOLER ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY
WATER PUMP ASSEMBLY
NOZZLE HOLDER ASSEMBLY
TURBOCHARGER ASSEMBLY
THERMOSTAT ASSEMBLY
ENGINE FRONT SEAL
ENGINE REAR SEAL
CYLINDER HEAD ASSEMBLY
AFTERCOOLER ASSEMBLY
HYDRAULIC COOLER ASSEMBLY
RADIATOR, HYDRAULIC COOLER ASSEMBLY
ENGINE, MAIN PUMP ASSEMBLY
DAMPER ASSEMBLY
FUEL TANK ASSEMBLY
CENTER SWIVEL JOINT ASSEMBLY
FINAL DRIVE ASSEMBLY
TRAVEL MOTOR ASSEMBLY
SPROCKET
SWING MOTOR ASSEMBLY
SWING MACHINERY ASSEMBLY
REVOLVING FRAME ASSEMBLY
SWING CIRCLE ASSEMBLY
IDLER, RECOIL SPRING ASSEMBLY
IDLER ASSEMBLY
RECOIL SPRING ASSEMBLY
TRACK ROLLER ASSEMBLY
CARRIER ROLLER ASSEMBLY
TRACK SHOE ASSEMBLY
HYDRAULIC TANK ASSEMBLY
CONTROL PUMP ASSEMBLY
MAIN PUMP ASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL
CONTROL VALVE ASSEMBLY
PUMP MERGE/DIVIDER VALVE ASSEMBLY
PRESSURE COMPENSATION VALVE ASSEMBLY
SERVO VALVE ASSEMBLY FOR FRONT PUMP
SERVO VALVE ASSEMBLY FOR REAR PUMP
PPC LOCK AND SWING BRAKE SOLENOID VALVE ASSEMBLY
MERGE/FLOW DIVIDER AND TRAVEL HI/LO SOLENOID VALVE ASSEMBLY
WORK EQUIPMENT PPC VALVE ASSEMBLY
TRAVEL PPC VALVE ASSEMBLY
PPC SHUTTLE VALVE ASSEMBLY
BOOM LOCK VALVE ASSEMBLY
BOOM CYLINDER ASSEMBLY
ARM CYLINDER ASSEMBLY
BUCKET CYLINDER ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
WORK EQUIPMENT ASSEMBLY
BUCKET ASSEMBLY
ARM ASSEMBLY
BUCKET, ARM ASSEMBLY
BOOM ASSEMBLY
OPERATOR’S CAB ASSEMBLY
MONITOR ASSEMBLY
COUNTERWEIGHT ASSEMBLY
CONTROL STAND CASE
AIR CONDITIONER COMPRESSOR ASSEMBLY
CONDENSER ASSEMBLY
AIR CONDITIONER UNIT ASSEMBLY
40 MAINTENANCE STANDARD
ENGINE MOUNT
SWING MACHINERY
SWING CIRCLE
FINAL DRIVE
TRACK FRAME AND RECOIL SPRING
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK
HYDRAULIC PUMP
CONTROL PUMP AND RELIEF VALVE
CONTROL VALVE
SUCTION-SAFETY VALVE
SWING MOTOR
TRAVEL MOTOR
WORK EQUIPMENT, SWING PPC VALVE
TRAVEL PPC VALVE
SERVICE PPC VALVE
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
CENTER SWIVEL JOINT
BOOM HOLDING VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
90 OTHERS
HYDRAULIC PIPING DIAGRAM (10-12)
HYDRAULIC CIRCUIT DIAGRAM (10-13)
OPERATION FOR EACH FUNCTION OF CLSS (10-50)
OPERATION OF WHOLE CLSS SYSTEM
ACTUAL ELECTRIC WIRING DIAGRAM (10-134)
ACTUAL ELECTRIC WIRING DIAGRAM (10-135)
ELECTRIC CIRCUIT DIAGRAM (10-136)
ELECTRIC CIRCUIT DIAGRAM (10-137)
CONNECTOR ARRANGEMENT DIAGRAM (20-114)