SEN02655-01 50 Disassembly and assembly

26 PC400, 450-8

40. Remove rocker housing (71). [*16]

41. Removal of cylinder head assembly [*17]1) Remove each set of 7 mounting bolts (74)

of cylinder head assembly (73).2) Using eyebolt [1], lift and remove cylinder

head assembly (73).

4 Cylinder head assembly: 20 kg3) Remove each head gasket.

Installationq Carry out installation in the reverse order to

removal.

[*1]3 Hose clamp: 9.8 ± 0.5 Nm {100 ± 5 kgcm}

[*2]3 Radiator-related hose clamp:

3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}

[*3]3 Fuel filter joint bolt:

24.5 – 34.5 Nm {2.5 – 3.5 kgm}

[*4]Keep the harness assembly and other harnesses10 mm and above away from the high-pressuretube.

[*5]Tighten the air intake manifold assembly mountingbolts in the order given below.

3 Intake manifold assembly:59 – 74 Nm {6 – 7.5 kgm}

[*6]3 Lubrication tube sleeve nut:

40 – 44 Nm {4.1 – 4.5 kgm}

[*7]Tighten the exhaust manifold assembly mountingbolts in the order given below, then tighten otherbolts.3 Exhaust manifold assembly mounting bolt:

58.8 – 73.5 Nm {6 – 7.5 kgm}

50 Disassembly and assembly SEN02655-01

PC400, 450-8 27

[*8]a For details on and how to install the high-pres-

sure tube cover, see Paragraph [*5] in"Removal and installation of fuel injectorassembly."

High-pressure tube installation instructionsa Don't correct high-pressure tube by bending it

for re-use.1) Tighten high-pressure tube permanently.

3 Sleeve nut:39.2 – 49 Nm {4 – 5 kgm}

2) Temporarily tighten high-pressure clamp andbrackets all by hand.

3) Tighten high-pressure tube clamp perma-nently.3 Clamp nut:

11.8 – 14.7 Nm {1.2 – 1.5 kgm}4) Tighten bracket permanently.5) Install cover.

a Direct the slit to the side of cylinder head.6) Temporarily install gate-type bracket and cover

(also working as clamp).7) Tighten the cover permanently.

3 Cover mounting bolt:11.8 – 14.7 Nm {1.2 – 1.5 kgm}

8) Tighten the gate-type bracket permanently.

[*9]3 Spill tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*10]3 Air vent tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*11]3 Head cover mounting bolt:

9.8 ± 1 Nm {1.0 ± 0.1 kgm}

[*12]a Tighten the capture nuts alternately.3 Capture nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}

[*13]1) Loosen locknut, then install rocker arm and

rocker shaft assembly.3 Rocker shaft mounting bolt:

58.8 – 73.5 Nm {6 – 7.5 kgm}2) Remove the cover and adjust the valve clear-

ance.Pointer is located under the cover.q Valve clearance

Intake : 0.33 mmExhaust : 0.71 mm

a See the paragraph of “Adjusting valve clear-ance” in the part for Testing and adjusting forthe valve clearance instructions.3 Rocker arm locknut:

58.8 – 73.5 Nm {6 – 7.5 kgm}

[*14]a For the mounting instructions of injector and

holder, see the paragraph for the "Removaland installation of fuel injector assembly."

[*15]a Amply apply engine oil (EO30-CD) to cross-

head guide and crosshead top face.a Adjust the crosshead according to the follow-

ing procedure.1) Loosen the locknut and return the adjust-

ment screw fully.2) Holding the top of the crosshead lightly,

tighten the adjustment screw while keep-ing the crosshead in contact with the valvestem.

3) After the adjustment screw touches thevalve stem, tighten it further by 20°.

4) Tighten the locknut at this position.3 Locknut:

58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}

[*16]3 Rocker housing mounting bolt:

58.8 – 73.5 Nm {6 – 7.5 kgm}

SEN02655-01 50 Disassembly and assembly

28 PC400, 450-8

[*17]a Clean the bottom face, block top face and liner

with dry cloth or soaked with a solvent.a Replace a bolt having 5 punch marks to the

bolt head.a Tighten the bolt with hand and screw in to the

block by turning the bolt at least 2 rounds.2 Bolt threaded portion and under side of

the bolt head:LM-P or engine oil (EO30-CD)

a Tighten the cylinder head mounting bolts in theorder indicated in the figure.3 Cylinder head mounting bolt 1 – 6:

1st time: 98.1 ± 9.8 Nm {10 ± 1 kgm}2nd time: 166.6 – 176.4 Nm {17 – 18kgm}3rd time: Tighten bolt to 90 to 120°(target 120°) using tool A9.

a When not using tool A8After applying a paint marking to the cylinderhead and bolt, tighten the bolt by 90° to 120°(target 120°).

a After tightening bolts 1 – 6, tighten auxiliarybolt 7.3 Cylinder head mounting auxiliary bolt:

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

a After tightening the bolt, punch a mark (c) onits head.

a When using a new bolt, do not punch a markon its head.

q Feed coolantFeed coolant from the radiator coolant filler tothe specified level. Start the engine and allowthe coolant to circulate the piping. Check thecoolant level.

5 Coolant: 36 l

50 Disassembly and assembly SEN02655-01

PC400, 450-8 29

Removal and installation of radiator assembly 1

Removalk Disconnect the negative (–) terminal from

the battery.1. Remove covers (1) and (2).

2. Drain coolant.

6 Coolant: 36 l3. Disconnect connector (P24) and overflow tube

(3) and remove the sub-tank (4).4. Remove the mounting bolt and then hoist the

engine hood assembly (5) to remove.

4 Engine hood: 200 kg

5. Remove the clamp and hoses (6), (7), (8) and(9) between the radiator and the engine. [*1]

6. Remove radiator front cover (10).

7. Remove undercover.8. Remove cover (11).9. Disconnect the lower hose (12).

10. Remove 2 upper mounting bolts (13).

SEN02655-01 50 Disassembly and assembly

30 PC400, 450-8

11. Lift and remove radiator assembly (14).

4 Radiator assembly: 30 kgInstallationq Carry out installation in the reverse order to

removal.

q Feed coolantFeed coolant from the radiator coolant filler tothe specified level. Start the engine and allowthe coolant to circulate the piping. Check thecoolant level again.

5 Coolant: 35 l

[*1]3 Radiator-related hose clamp

(8) : 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}(7) : 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}(6) : 8.8 ± 0.49 Nm {0.9 ± 0.05 kgm}

COVER00 Index and forewordIndexComposition of shop manualTable of contents

Foreword and general informationSafety noticeHow to read the shop manualExplanation of terms for maintenance standardHandling of electric equipment and hydraulic componentHandling of connectors newly used for enginesHow to read electric wire codePrecautions when carrying out operationMethod of disassembling and connecting push-pull type couplerStandard tightening torque tableConversion table

01 SpecificationSpecification and technical dataSpecification dimension drawingsSpecificationsWeight tableTable of fuel, coolant and lubricants

10 Structure, function and maintenance standardEngine and cooling systemEngine related partsRadiator, oil cooler and aftercooler

Power trainPower trainSwing circleSwing machineryFinal driveSprocket

Undercarriage and frameTrack frame and recoil springIdlerCarrier rollerTrack rollerTrack shoe

Hydraulic system, Part 1Hydraulic equipment layout drawingHydraulic tank and filterHydraulic pump

Hydraulic system, Part 2Control valveCLSSFunctions and operation by valveMerge-divider valveAttachment circuit selector valveHolding valve

Hydraulic system, Part 3Valve controlPPC valveSolenoid valvePPC accumulatorReturn oil filterCenter swivel jointTravel motorSwing motorHydraulic cylinder

Work equipmentWork equipmentDimensions of components

Cab and its attachmentsAir conditioner piping

Electrical systemEngine controlElectrical control systemMonitor systemSensorsKOMTRAX terminal system

20 Standard value tableStandard service value tableStandard value table for engineStandard value table for chassis related partsStandard value table for chassis related parts (Loading shovel specification)

30 Testing and adjustingTesting and adjusting, Part 1Tools for testing, adjusting and troubleshootingSketches of special toolsTesting engine speedTesting air boost pressureTesting exhaust temperatureTesting exhaust gas colorAdjusting valve clearanceTesting compression pressureTesting blow-by pressureTesting engine oil pressureTesting EGR valve drive pressureHandling fuel system partsReleasing residual pressure from fuel systemTesting fuel pressureHandling during cylinder cut-out operationHandling during no injection cranking operationTesting fuel return and leakageBleeding air from fuel circuitChecking fuel circuit for leakageChecking and adjusting fan belt and alternator beltChecking and adjusting air conditioner compressor belt tensionTesting swing circle bearing clearanceChecking and adjusting track shoe tensionTesting and adjustment oil pressure in work equipment, swing, and travel circuitsTesting control circuit basic pressureChecking and adjusting pump PC control circuit oil pressureChecking and adjusting pump LS control circuit oil pressureTesting solenoid valve output pressureTesting PPC valve output pressureAdjusting play of work equipment and swing PPC valvesInspecting locations of hydraulic drift of work equipmentReleasing residual pressure from hydraulic circuitTesting oil leakage amountBleeding air from various parts

Testing and adjusting, Part 2Special functions of machine monitor

Testing and adjusting, Part 3Handling voltage circuit of engine controllerPreparation work for troubleshooting of electrical systemProcedure for testing diodesPm Clinic serviceUndercarriage troubleshooting report

40 TroubleshootingFailure code table and fuse locationsFailure code tableFuse locations

General Information on troubleshootingPoints to remember when troubleshootingSequence of events in troubleshootingCheck before troubleshootingClassification and troubleshooting stepsInformation in troubleshooting tablePossible problems and troubleshooting No.Connection table for connector pin numbersT- branch box and T- branch adapter table

Troubleshooting by failure code, Part 1Failure code [989L00] Engine Controller Lock Caution 1Failure code [989M00] Engine Controller Lock Caution 2Failure code [989N00] Engine Controller Lock Caution 3Failure code [AA10NX] Air cleaner CloggingFailure code [AB00KE] Charge Voltage LowFailure code [B@BAZG] Eng Oil Press LowFailure code [B@BAZK] Eng Oil Level LowFailure code [B@BCNS] Eng Water OverheatFailure code [B@BCZK] Eng Water Level LowFailure code [B@HANS] Hydr Oil OverheatFailure code [CA111] EMC Critical Internal FailureFailure code [CA115] Eng Ne and Bkup Speed Sens ErrorFailure code [CA122] Chg Air Press Sensor High ErrorFailure code [CA123] Chg Air Press Sensor Low ErrorFailure code [CA131] Throttle Sensor High ErrorFailure code [CA132] Throttle Sensor Low ErrorFailure code [CA135] Eng Oil Press Sensor High ErrorFailure code [CA141] Eng Oil Press Sensor Low ErrorFailure code [CA144] Coolant Temp Sensor High ErrorFailure code [CA145] Coolant Temp Sensor Low ErrorFailure code [CA153] Chg Air Temp Sensor High ErrorFailure code [CA154] Chg Air Temp Sensor Low ErrorFailure code [CA187] Sens Supply 2 Volt Low ErrorFailure code [CA221] Ambient Press Sens High ErrorFailure code [CA222] Ambient Press Sens Low ErrorFailure code [CA227] Sens Supply 2 Volt High ErrorFailure code [CA234] Eng OverspeedFailure code [CA238] Ne Speed Sens Supply Volt ErrorFailure code [CA263] Fuel Temp Sensor High ErrorFailure code [CA265] Fuel Temp Sensor Low ErrorFailure code [CA271] IMV/PCV1 Short ErrorFailure code [CA272] IMV/PCV1 Open ErrorFailure code [CA273] PCV2 Short ErrorFailure code [CA274] PCV2 Open ErrorFailure code [CA322] Inj #1 Open/Short ErrorFailure code [CA323] Inj #5 (L/B#5) Open/Short ErrorFailure code [CA324] Inj #3 (L/B#3) Open/Short ErrorFailure code [CA325] Inj #6 Open/Short ErrorFailure code [CA331] Inj #2 Open/Short ErrorFailure code [CA332] Inj #4 Open/Short Error

Troubleshooting by failure code, Part 2Failure code [CA342] Calibration Code IncompatibilityFailure code [CA351] Injectors Drive Circuit ErrorFailure code [CA352] Sens Supply 1 Volt Low ErrorFailure code [CA386] Sens Supply 1 Volt High ErrorFailure code [CA441] Battery Voltage Low ErrorFailure code [CA442] Battery Voltage High ErrorFailure code [CA449] Rail Press Very High ErrorFailure code [CA451] Rail Press Sensor High ErrorFailure code [CA452] Rail Press Sensor Low ErrorFailure code [CA553] Rail Press High ErrorFailure code [CA554] Rail Press Sensor In Range ErrorFailure code [CA559] Rail Press Low ErrorFailure code [CA689] Eng Ne Speed Sensor ErrorFailure code [CA731] Eng Bkup Speed Sens Phase ErrorFailure code [CA757] All Continuous Data Lost ErrorFailure code [CA778] Eng Bkup Speed Sensor ErrorFailure code [CA1228] EGR valve servo error 1Failure code [CA1625] EGR valve servo error 2Failure code [CA1633] KOMNET Datalink Timeout ErrorFailure code [CA2185] Throt Sens Sup Volt High ErrorFailure code [CA2186] Throt Sens Sup Volt Low ErrorFailure code [CA2249] Rail Press Very Low ErrorFailure code [CA2271] EGR valve lift sensor high errorFailure code [CA2272] EGR valve lift sensor low errorFailure code [CA2351] EGR valve solenoid operation short circuitFailure code [CA2352] EGR valve solenoid operation disconnectFailure code [CA2555] Grid Htr Relay Volt Low ErrorFailure code [CA2556] Grid Htr Relay Volt High ErrorFailure code [D110KB] Battery Relay Drive S/CFailure code [D19JKZ] Personal Code Relay AbnormalityFailure code [D862KA] GPS Antenna DisconFailure code [DA22KK] Pump Solenoid Power Low ErrorFailure code [DA25KP] 5V sensor power supply output 1 abnormalityFailure code [DA29KQ] Model Selection Abnormality

Troubleshooting by failure code, Part 3Failure code [DA2RMC] CAN Discon (Pump con detected)Failure code [DAF8KB] Short circuit in camera power supplyFailure code [DAFGMC] GPS Module ErrorFailure code [DAFRMC] CAN discon (Monitor detected)Failure code [DGH2KB] Hyd Oil Sensor ShortFailure code [DHPAMA] F Pump Press Sensor AbnormalityFailure code [DHPBMA] R Pump Press Sensor AbnormalityFailure code [DHS3MA] Arm Curl PPC Press Sensor AbnormalityFailure code [DHS4MA] Bucket Curl PPC Press Sensor AbnormalityFailure code [DHX1MA] Overload Sensor Abnormality (Analog)Failure code [DW43KA] Travel Speed Sol. Open CircuitFailure code [DW43KB] Travel Speed Sol. Short CircuitFailure code [DW45KA] Swing Brake Sol. Open CircuitFailure code [DW45KB] Swing Brake Sol. Short CircuitFailure code [DW91KA] Travel Junction Sol.Open CircuitFailure code [DW91KB] Travel Junction Sol. Short CircuitFailure code [DWA2KA] Attachment Sol Open CircuitFailure code [DWA2KB] Attachment Sol Short CircuitFailure code [DWJ0KA] Merge-divider Sol. Open CircuitFailure code [DWJ0KB] Merge-divider Sol. Short CircuitFailure code [DWK0KA] 2-stage Relief Sol. Open CircuitFailure code [DWK0KB] 2-stage Relief Sol. Short CircuitFailure code [DXA0KA] PC-EPC Sol. Open CircuitFailure code [DXA0KB] PC-EPC Sol. Short CircuitFailure code [DXE0KA] LS-EPC Sol. Open CircuitFailure code [DXE0KB] LS-EPC Sol. Short CircuitFailure code [DXE4KA] Service Current EPC Open CircuitFailure code [DXE4KB] Service Current EPC Short CircuitFailure code [DY20KA] Wiper Working AbnormalityFailure code [DY20MA] Wiper Parking AbnormalityFailure code [DY2CKA] Washer Drive Open DisconFailure code [DY2CKB] Washer Drive Short CircuitFailure code [DY2DKB] Wiper Drive (Fwd) Short CircuitFailure code [DY2EKB] Wiper Drive (Rev) Short Circuit

Troubleshooting of electrical system (E-mode)Before carrying out troubleshooting of electrical systemInformation contained in troubleshooting tableE-1 Engine does not startE-2 Auto-decelerator does not operateE-3 Automatic warming-up system does not operateE-4 Preheater does not operateE-5 All work equipment, swing, and travel mechanism do not moveE-6 Power maximizing function does not operateE-7 Machine monitor does not display at allE-8 Machine monitor does not display some itemsE-9 Contents of display by machine monitor are different from applicable machineE-10 Fuel level monitor was lighted in red while engine runningE-11 Engine coolant temperature gauge does not indicate normallyE-12 Hydraulic oil temperature gauge does not indicate normallyE-13 Fuel level gauge does not indicate normallyE-14 Swing lock monitor does not indicate normallyE-15 When monitor switch is operated, monitor displays nothingE-16 Windshield wiper and window washer do not operateE-17 Machine push-up function does not operate normallyE-18 Monitoring function fails to display “boom raise” normallyE-19 Monitoring function fails to display “boom lower” normallyE-20 Monitoring function fails to display “arm IN” normallyE-21 Monitoring function fails to display “arm OUT” normallyE-22 Monitoring function fails to display “bucket CURL” normallyE-23 Monitoring function fails to display “bucket DUMP” normallyE-24 Monitoring function fails to display “swing” normallyE-25 Monitoring function fails to display “travel” normallyE-26 Monitoring function fails to display “travel differential pressure” normallyE-27 Monitoring function fails to display “service” normallyE-28 KOMTRAX system does not operate normallyE-29 Air conditioner does not operateE-30 Travel alarm does not sound or does not stop soundingE-31 Horn does not sound

Troubleshooting of hydraulic and mechanical system (H-mode)System chart for hydraulic and mechanical systemInformation contained in troubleshooting tableH-1 All work equipment lack power, or travel and swing speeds are slowH-2 Engine speed sharply drops or engine stallsH-3 No work equipment, swing or travel moveH-4 Abnormal noise is heard from around hydraulic pumpH-5 Auto-decelerator does not workH-6 Fine control mode does not function or responds slowH-7 Boom moves slowly or lacks powerH-8 Arm moves slowly or lacks powerH-9 Bucket moves slowly or lacks powerH-10 Work equipment does not move in its single operationH-11 Work equipment has a bit too fast hydraulic driftH-12 Work equipment has big time lagH-13 Other work equipment moves when relieving single circuitH-14 Power max. switch does not operateH-15 Machine push-up function does not operate.H-16 In compound operation of work equipment, speed of part loaded more is lowH-17 When machine swings and raises boom simultaneously, boom rising speed is lowH-18 When machine swings and travels simultaneously, travel speed lowers largelyH-19 Machine deviates during travelH-20 Travel speed is lowH-21 Machine is not steered well or steering power is lowH-22 Travel speed does not change or travel speed is low or highH-23 Travel system does not move (only one side)H-24 Upper structure does not swingH-25 Swing acceleration or swing speed is lowH-26 Upper structure overruns remarkably when it stops swingingH-27 Large shock is made when upper structure stops swingingH-28 Large sound is made when upper structure stops swinging.H-29 Hydraulic drift of swing is largeH-30 Attachment circuit is not changedH-31 Oil flow in attachment circuit cannot be controlled

Troubleshooting of engine (S-mode)Method of using troubleshooting chartS-1 Starting performance is poorS-2 Engine does not startS-3 Engine does not pick up smoothlyS-4 Engine stops during operationsS-5 Engine does not rotate smoothlyS-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 quicklyS-10 Fuel consumption is excessiveS-11 Oil is in coolant (or coolant spurts back or coolant level goes down)S-12 Oil pressure dropsS-13 Oil level rises (Entry of coolant or fuel)S-14 Coolant temperature becomes too high (overheating)S-15 Abnormal noise is madeS-16 Vibration is excessive

50 Disassembly and assemblyGeneral information on disassembly and assemblyHow to read this manualCoating materials listSpecial tool listSketches of special tools

Engine and cooling systemRemoval and installation of fuel supply pump assemblyRemoval and installation of fuel injector assemblyRemoval and installation of engine front sealRemoval and installation of engine rear sealRemoval and installation of cylinder head assemblyRemoval and installation of radiator assemblyRemoval and installation of hydraulic oil cooler assemblyRemoval and installation of aftercooler assemblyRemoval and installation of engine and hydraulic oil pump assembly

Power trainRemoval and installation of travel motor and final drive assemblyDisassembly and assembly of final drive assemblyRemoval and installation of swing motor and swing machinery assemblyDisassembly and assembly of swing motor and swing machinery assemblyRemoval and installation of swing circle assembly

Undercarriage and frameDisassembly and assembly of carrier roller assemblyDisassembly and assembly of track roller assemblyDisassembly and assembly of idler assemblyDisassembly and assembly of recoil spring assemblyRemoval and installation of sprocketExpansion and installation of track shoe assemblyRemoval and installation of revolving frame assemblyRemoval and installation of counterweight assembly

Hydraulic systemRemoval and installation of center swivel joint assemblyDisassembly and assembly of center swivel joint assemblyRemoval and installation of hydraulic tank assemblyRemoval and installation of control valve assemblyDisassembly and assembly of control valve assemblyRemoval and installation of hydraulic pump assemblyRemoval and installation of oil seal in hydraulic pump input shaftDisassembly and assembly of work equipment PPC valve assemblyDisassembly and assembly of travel PPC valve assemblyDisassembly and assembly of hydraulic cylinder assembly

Work equipmentRemoval and installation of work equipment assembly

Cab and its attachmentsRemoval and installation of operator cab assemblyRemoval and installation of operator cab glass (stuck glass)Removal and installation of front window assemblyRemoval and installation of floor frame assembly

Electrical systemRemoval and installation of air conditioner unit assemblyRemoval and installation of KOMTRAX communication modem assemblyRemoval and installation of monitor assemblyRemoval and installation of pump controller assemblyRemoval and installation of engine controller

90 Diagrams and drawingsHydraulic diagrams and drawingsHydraulic circuit diagram

Electrical diagrams and drawingsElectrical circuit diagramConnector list and stereogram