Komatsu Hydraulic Excavator Pc400 8 88888 Shop Manual

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CEBM018803

Shop
Manual

PC400LC-8
HYDRAULIC EXCAVATOR

SERIAL NUMBERS PC400LC-8 A88001 - A88545

ENGINE SAA6D125E-5

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

August 2011 Copyright 2011 Komatsu

Printed in USA DataKom Publishing Division
00-1d

This is the cut pages sample. Download all 1043 page(s) at: ManualPlace.com
FOREWORD CONTENTS
12
CONTENTS 00

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

20 STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

90 DIAGRAMS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

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FOREWORD

The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add

● Page to be replaced Replace

( ) Page to be deleted Discard

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● 00-1 d ● 00-20 d 10-7 10-36

● 00-2 d ● 00-21 d 10-8 10-37

● 00-2-1 d ● 00-22 d ● 10-9 d 10-38

● 00-2-2 d ● 00-23 d ● 10-10 d 10-39 c

● 00-2-3 d ● 00-24 d 10-11 10-40 c

● 00-2-4 d ● 00-25 d 10-12 10-41 c

● 00-2-5 d ● 00-26 d ● 10-13 d 10-42 c

● 00-2-6 d ● 00-27 d ● 10-14 d 10-43 c

● 00-2-7 d ● 00-28 d 10-15 10-44

● 00-2-8 d 10-16 10-45

● 00-2-9 d ● 01-1 d ● 10-17 d 10-46

● 00-2-10 d ● 01-2 d 10-18 10-47

● 00-3 d ● 01-3 d ● 10-19 d 10-48

● 00-4 d 01-4 c ● 10-20 d 10-49

● 00-5 d 01-5 10-21 ● 10-50 d

● 00-6 d 01-6 c 10-22 ● 10-51 d

● 00-7 d 01-7 ● 10-23 d 10-52

● 00-8 d 01-8 ● 10-24 d 10-53

● 00-9 d 01-9 ● 10-25 d 10-54

● 00-10 d ● 01-10 d ● 10-26 d 10-55

● 00-11 d ● 01-11 d 10-27 10-56

● 00-12 d ● 01-12 d 10-28 ● 10-57 c

● 00-13 d 10-29 10-58

● 00-14 d ● 10-1 d 10-30 ● 10-59 d

● 00-15 d ● 10-2 d 10-31 10-60

● 00-16 d ● 10-3 d 10-32 ● 10-61 d

● 00-17 d 10-4 ● 10-33 d 10-62

● 00-18 d 10-5 ● 10-34 d ● 10-63 d

● 00-19 d 10-6 10-35 10-64

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● 10-65 d 10-98 10-131 10-164

10-66 10-99 10-132 10-165

● 10-67 d 10-100 10-133 10-166

10-68 c 10-101 10-134 10-167

10-69 10-102 10-135 10-168

10-70 10-103 10-136 c ● 10-169 d

10-71 c 10-104 ● 10-137 d 10-170

10-72 10-105 10-138 ● 10-171 d

10-73 ● 10-106 d 10-139 10-172

10-74 c 10-107 10-140 ● 10-173 d

10-75 10-108 10-141 10-174

10-76 10-109 10-142 ● 10-175 d

10-77 10-110 ● 10-143 d 10-176

10-78 c 10-111 10-144 10-177

10-79 ● 10-112 d ● 10-145 d 10-178

10-80 10-113 10-146 10-179

10-81 10-114 ● 10-147 d ● 10-180 d

10-82 ● 10-115 d 10-148 ● 10-181 d

10-83 10-116 c 10-149 ● 10-182 d

10-84 10-117 10-150 ● 10-183 d

10-85 10-118 10-151 10-184

10-86 10-119 10-152 10-185

10-87 10-120 10-153 10-186

10-88 10-121 10-154 10-187

10-89 10-122 10-155 10-188

10-90 ● 10-123 d 10-156 10-189

10-91 ● 10-124 d 10-157 10-190

10-92 10-125 10-158 10-191

10-93 ● 10-126 d ● 10-159 d 10-192

10-94 10-127 10-160 10-193

10-95 10-128 ● 10-161 d ● 10-194 d

10-96 ● 10-129 d 10-162 ● 10-195 d

10-97 ● 10-130 d 10-163 10-196

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10-197 10-230 20-10 ● 30-32 d

10-198 10-231 ● 30-33 d

10-199 c 10-232 ● 30-1 d ● 30-34 d

10-200 10-233 ● 30-2 d ● 30-35 d

10-201 c 10-234 ● 30-3 d ● 30-36 d

10-202 ● 10-235 d ● 30-4 d ● 30-37 d

10-203 10-236 ● 30-5 d ● 30-38 d

10-204 ● 10-237 d ● 30-6 d ● 30-39 d

10-205 ● 10-238 d ● 30-7 d ● 30-40 d

10-206 10-239 c ● 30-8 d ● 30-41 d

● 10-207 d 10-240 c ● 30-9 d ● 30-42 d

10-208 10-241 c ● 30-10 d ● 30-43 d

● 10-209 d 10-242 c ● 30-11 d ● 30-44 d

10-210 10-243 c ● 30-12 d ● 30-45 d

10-211 c 10-244 c ● 30-13 d ● 30-46 d

10-212 c 10-245 c ● 30-14 d ● 30-47 d

10-213 c ● 10-246 d ● 30-15 d ● 30-48 d

10-214 10-247 c ● 30-16 d ● 30-49 d

● 10-215 d 10-248 c ● 30-17 d ● 30-50 d

● 10-216 d 10-249 c ● 30-18 d ● 30-51 d

10-217 ● 10-250 d ● 30-19 d ● 30-52 d

10-218 ❍ 10-251 d ● 30-20 d ● 30-53 d

● 10-219 d ❍ 10-252 d ● 30-21 d ● 30-54 d

● 10-220 d ● 30-22 d ● 30-55 d

10-221 20-1 ● 30-23 d ● 30-56 d

10-222 ● 20-2 d ● 30-24 d ● 30-57 d

10-223 20-3 c ● 30-25 d ● 30-58 d

● 10-224 d ● 20-4 d ● 30-26 d ● 30-59 d

● 10-225 d 20-5 ● 30-27 d ● 30-60 d

● 10-226 d 20-6 ● 30-28 d ● 30-61 d

● 10-227 d 20-7 ● 30-29 d ● 30-62 d

10-228 ● 20-8 d ● 30-30 d ● 30-63 d

● 10-229 d ● 20-9 d ● 30-31 d ● 30-64 d

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● 30-65 d ● 30-98 d ● 30-131 d 40-19 c

● 30-66 d ● 30-99 d ● 30-132 d 40-20 c

● 30-67 d ● 30-100 d ● 30-133 d 40-21 c

● 30-68 d ● 30-101 d ● 30-134 d 40-22 c

● 30-69 d ● 30-102 d ● 30-135 d 40-23 c

● 30-70 d ● 30-103 d ● 30-136 d 40-24 c

● 30-71 d ● 30-104 d ● 30-137 d 40-25 c

● 30-72 d ● 30-105 d ● 30-138 d 40-26 c

● 30-73 d ● 30-106 d ● 30-139 d 40-27 c

● 30-74 d ● 30-107 d ● 30-140 d 40-28 c

● 30-75 d ● 30-108 d ● 30-141 d 40-29 c

● 30-76 d ● 30-109 d ● 30-142 d 40-30 c

● 30-77 d ● 30-110 d ● 30-143 d 40-31 c

● 30-78 d ● 30-111 d ● 30-144 d ● 40-32 d

● 30-79 d ● 30-112 d ● 40-33 d

● 30-80 d ● 30-113 d ● 40-1 d ● 40-34 d

● 30-81 d ● 30-114 d ● 40-2 d 40-35 c

● 30-82 d ● 30-115 d ● 40-3 d 40-36 c

● 30-83 d ● 30-116 d ● 40-4 d 40-37 c

● 30-84 d ● 30-117 d 40-5 c 40-38 c

● 30-85 d ● 30-118 d ● 40-6 d ● 40-39 d

● 30-86 d ● 30-119 d 40-7 c 40-40 c

● 30-87 d ● 30-120 d ● 40-8 d 40-41 c

● 30-88 d ● 30-121 d 40-9 c 40-42 c

● 30-89 d ● 30-122 d ● 40-10 d 40-43 c

● 30-90 d ● 30-123 d ● 40-11 d 40-44 c

● 30-91 d ● 30-124 d 40-12 c ● 40-45 d

● 30-92 d ● 30-125 d 40-13 c ● 40-46 d

● 30-93 d ● 30-126 d 40-14 c 40-47 c

● 30-94 d ● 30-127 d 40-15 c 40-48 c

● 30-95 d ● 30-128 d 40-16 c ● 40-49 d

● 30-96 d ● 30-129 d 40-17 c 40-50 c

● 30-97 d ● 30-130 d 40-18 c 40-51 c

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40-52 c ● 40-85 d ● 40-118 d ● 40-151 d

40-53 c ● 40-86 d ● 40-119 d ● 40-152 d

40-54 c ● 40-87 d ● 40-120 d ● 40-153 d

40-55 c ● 40-88 d ● 40-121 d ● 40-154 d

40-56 c ● 40-89 d ● 40-122 d ● 40-155 d

40-57 c ● 40-90 d ● 40-123 d ● 40-156 d

40-58 c ● 40-91 d ● 40-124 d ● 40-157 d

40-59 c ● 40-92 d ● 40-125 d ● 40-158 d

40-60 c ● 40-93 d ● 40-126 d ● 40-159 d

40-61 c ● 40-94 d ● 40-127 d ● 40-160 d

40-62 c ● 40-95 d ● 40-128 d ● 40-161 d

40-63 c ● 40-96 d ● 40-129 d ● 40-162 d

40-64 c ● 40-97 d ● 40-130 d ● 40-163 d

40-65 c ● 40-98 d ● 40-131 d ● 40-164 d

40-66 c ● 40-99 d ● 40-132 d ● 40-165 d

40-67 c ● 40-100 d ● 40-133 d ● 40-166 d

40-68 c ● 40-101 d ● 40-134 d ● 40-167 d

40-69 c ● 40-102 d ● 40-135 d ● 40-168 d

40-70 c ● 40-103 d ● 40-136 d ● 40-169 d

40-71 c ● 40-104 d ● 40-137 d ● 40-170 d

40-72 c ● 40-105 d ● 40-138 d ● 40-171 d

40-73 c ● 40-106 d ● 40-139 d ● 40-172 d

40-74 c ● 40-107 d ● 40-140 d ● 40-173 d

40-75 c ● 40-108 d ● 40-141 d ● 40-174 d

● 40-76 d ● 40-109 d ● 40-142 d ● 40-175 d

● 40-77 d ● 40-110 d ● 40-143 d ● 40-176 d

● 40-78 d ● 40-111 d ● 40-144 d ● 40-177 d

● 40-79 d ● 40-112 d ● 40-145 d ● 40-178 d

● 40-80 d ● 40-113 d ● 40-146 d ● 40-179 d

● 40-81 d ● 40-114 d ● 40-147 d ● 40-180 d

● 40-82 d ● 40-115 d ● 40-148 d ● 40-181 d

● 40-83 d ● 40-116 d ● 40-149 d ● 40-182 d

● 40-84 d ● 40-117 d ● 40-150 d ● 40-183 d

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● 40-184 d ● 40-217 d ● 40-250 d ● 40-283 d

● 40-185 d ● 40-218 d ● 40-251 d ● 40-284 d

● 40-186 d ● 40-219 d ● 40-252 d ● 40-285 d

● 40-187 d ● 40-220 d ● 40-253 d ● 40-286 d

● 40-188 d ● 40-221 d ● 40-254 d ● 40-287 d

● 40-189 d ● 40-222 d ● 40-255 d ● 40-288 d

● 40-190 d ● 40-223 d ● 40-256 d ● 40-289 d

● 40-191 d ● 40-224 d ● 40-257 d ● 40-290 d

● 40-192 d ● 40-225 d ● 40-258 d ● 40-291 d

● 40-193 d ● 40-226 d ● 40-259 d ● 40-292 d

● 40-194 d ● 40-227 d ● 40-260 d ● 40-293 d

● 40-195 d ● 40-228 d ● 40-261 d ● 40-294 d

● 40-196 d ● 40-229 d ● 40-262 d ● 40-295 d

● 40-197 d ● 40-230 d ● 40-263 d ● 40-296 d

● 40-198 d ● 40-231 d ● 40-264 d ● 40-297 d

● 40-199 d ● 40-232 d ● 40-265 d ● 40-298 d

● 40-200 d ● 40-233 d ● 40-266 d ● 40-299 d

● 40-201 d ● 40-234 d ● 40-267 d ● 40-300 d

● 40-202 d ● 40-235 d ● 40-268 d ● 40-301 d

● 40-203 d ● 40-236 d ● 40-269 d ● 40-302 d

● 40-204 d ● 40-237 d ● 40-270 d ● 40-303 d

● 40-205 d ● 40-238 d ● 40-271 d ● 40-304 d

● 40-206 d ● 40-239 d ● 40-272 d ● 40-305 d

● 40-207 d ● 40-240 d ● 40-273 d ● 40-306 d

● 40-208 d ● 40-241 d ● 40-274 d ● 40-307 d

● 40-209 d ● 40-242 d ● 40-275 d ● 40-308 d

● 40-210 d ● 40-243 d ● 40-276 d ● 40-309 d

● 40-211 d ● 40-244 d ● 40-277 d ● 40-310 d

● 40-212 d ● 40-245 d ● 40-278 d ● 40-311 d

● 40-213 d ● 40-246 d ● 40-279 d ● 40-312 d

● 40-214 d ● 40-247 d ● 40-280 d ● 40-313 d

● 40-215 d ● 40-248 d ● 40-281 d ● 40-314 d

● 40-216 d ● 40-249 d ● 40-282 d ● 40-315 d

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● 40-316 d ● 40-349 d 50-5 c 50-38 c

● 40-317 d ● 40-350 d 50-6 c 50-39 c

● 40-318 d ● 40-351 d 50-7 c 50-40 c

● 40-319 d ● 40-352 d 50-8 c 50-41 c

● 40-320 d ● 40-353 d 50-9 c 50-42 c

● 40-321 d ● 40-354 d 50-10 c 50-43 c

● 40-322 d ● 40-355 d ● 50-11 d 50-44 c

● 40-323 d ● 40-356 d 50-12 c 50-45 c

● 40-324 d ● 40-357 d 50-13 c 50-46 c

● 40-325 d ● 40-358 d 50-14 c 50-47 c

● 40-326 d ● 40-359 d 50-15 c ● 50-48 d

● 40-327 d ● 40-360 d 50-16 c 50-49 c

● 40-328 d ● 40-361 d 50-17 c 50-50 c

● 40-329 d ● 40-362 d 50-18 c 50-51 c

● 40-330 d ● 40-363 d 50-19 c 50-52 c

● 40-331 d ● 40-364 d 50-20 c 50-53 c

● 40-332 d ● 40-365 d 50-21 c 50-54 c

● 40-333 d ● 40-366 d 50-22 c 50-55 c

● 40-334 d ● 40-367 d 50-23 c 50-56 c

● 40-335 d ● 40-368 d 50-24 c 50-57 c

● 40-336 d ● 40-369 d 50-25 c 50-58 c

● 40-337 d ● 40-370 d 50-26 c 50-59 c

● 40-338 d ● 40-371 d ● 50-27 d 50-60 c

● 40-339 d ● 40-372 d 50-28 c 50-61 c

● 40-340 d ● 40-373 d 50-29 c 50-62 c

● 40-341 d ● 40-374 d 50-30 c ● 50-63 d

● 40-342 d ● 40-375 d 50-31 c 50-64 c

● 40-343 d ● 40-376 d 50-32 c 50-65 c

● 40-344 d 50-33 c 50-66 c

● 40-345 d ● 50-1 d 50-34 c 50-67 c

● 40-346 d ● 50-2 d 50-35 c 50-68 c

● 40-347 d ● 50-3 d 50-36 c 50-69 c

● 40-348 d 50-4 c 50-37 c 50-70 c

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50-71 c 50-104 c ● 50-137 d ● 50-170 d

50-72 c 50-105 c ● 50-138 d ● 50-171 d

50-73 c 50-106 c ● 50-139 d ● 50-172 d

50-74 c 50-107 c ● 50-140 d ● 50-173 d

50-75 c 50-108 c ● 50-141 d ● 50-174 d

50-76 c ● 50-109 d ● 50-142 d ● 50-175 d

50-77 c ● 50-110 d ● 50-143 d ● 50-176 d

50-78 c 50-111 c ● 50-144 d ● 50-177 d

50-79 c 50-112 c ● 50-145 d ● 50-178 d

50-80 c 50-113 c ● 50-146 d ● 50-179 d

50-81 c 50-114 c ● 50-147 d ● 50-180 d

50-82 c 50-115 c ● 50-148 d ● 50-181 d

50-83 c 50-116 c ● 50-149 d ● 50-182 d

50-84 c 50-117 c ● 50-150 d ● 50-183 d

50-85 c ● 50-118 d ● 50-151 d ● 50-184 d

50-86 c ● 50-119 d ● 50-152 d ● 50-185 d

50-87 c ● 50-120 d ● 50-153 d ● 50-186 d

50-88 c ● 50-121 d ● 50-154 d ● 50-187 d

50-89 c ● 50-122 d ● 50-155 d ● 50-188 d

50-90 c ● 50-123 d ● 50-156 d ● 50-189 d

50-91 c ● 50-124 d ● 50-157 d ● 50-190 d

50-92 c ● 50-125 d ● 50-158 d ● 50-191 d

50-93 c ● 50-126 d ● 50-159 d ● 50-192 d

50-94 c ● 50-127 d ● 50-160 d ● 50-193 d

50-95 c ● 50-128 d ● 50-161 d ● 50-194 d

50-96 c ● 50-129 d ● 50-162 d ● 50-195 d

50-97 c ● 50-130 d ● 50-163 d ● 50-196 d

50-98 c ● 50-131 d ● 50-164 d ● 50-197 d

50-99 c ● 50-132 d ● 50-165 d ● 50-198 d

50-100 c ● 50-133 d ● 50-166 d ● 50-199 d

50-101 c ● 50-134 d ● 50-167 d ● 50-200 d

50-102 c ● 50-135 d ● 50-168 d ● 50-201 d

50-103 c ● 50-136 d ● 50-169 d ● 50-202 d

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● 90-1 d

● 90-2 d

● 90-3 d

● 90-4 d

● 90-5 d

● 90-6 d

● 90-7 d

❍ 90-8 d

❍ 90-9 d

❍ 90-10 d

❍ 90-11 d

❍ 90-12 d

❍ 90-13 d

❍ 90-14 d

❍ 90-15 d

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FOREWORD SAFETY
12
SAFETY 00

Safety Notice 00

Important Safety Notice 00

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying
these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider
safety, and take the necessary actions to deal with the situation.

General Precautions 00

6. Decide a place in the repair workshop to keep tools and

Mistakes in operation are extremely dangerous. Read the removed parts. Always keep the tools and parts in their
OPERATION & MAINTENANCE MANUAL carefully correct places. Always keep the work area clean and
BEFORE operating the machine. make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
1. Before carrying out any greasing or repairs, read all the while working.
precautions given on the decals which are fixed to the
machine.

2. When carrying out any operation, always wear safety

Preparations For Work
shoes and helmet. Do not wear loose work clothes, or
00

clothes with buttons missing. 1. Before adding oil or making repairs, park the machine
• Always wear safety glasses when hitting parts with on hard, level ground, and block the wheels or tracks to
a hammer. prevent the machine from moving.
• Always wear safety glasses when grinding parts
with a grinder, etc. 2. Before starting work, lower blade, ripper, bucket or any
other work equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent
3. If welding repairs are needed, always have a trained,
the work equipment from falling. In addition, be sure to
experienced welder carry out the work. When carrying
lock all the control levers and hang warning signs on
out welding work, always wear welding gloves, apron,
them.
glasses, cap and other clothes suited for welding work.
3. When disassembling or assembling, support the
machine with blocks, jacks or stands before starting
WARNING! Never modify, weld, cut, or work.
drill on any part of a ROPS
structure. Doing so may 4. Remove all mud and oil from the steps or other places
weaken the structure which used to get on and off the machine. Always use the
could lead to possible failure handrails, ladders or steps when getting on or off the
in a rollover situation. machine. Never jump on or off the machine. If it is
impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.

4. When carrying out any operation with two or more Precautions During Work 00

workers, always agree on the operating procedure

1. When removing the oil filler cap, drain plug or
before starting. Always inform your fellow workers
hydraulic pressure measuring plugs, loosen them slowly
before starting any step of the operation. Before starting
to prevent the oil from spurting out. Before
work, hang UNDER REPAIR signs on the controls in
disconnecting or removing components of the oil, water
the operator's compartment.
or air circuits, first remove the pressure completely from
the circuit.
5. Keep all tools in good condition and learn the correct
way to use them.

PC400LC-8 00-3 d
FOREWORD SAFETY
2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and
water to cool before carrying out any work on the oil or water circuits.

3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-)
terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.

5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.

8. Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean parts.

9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.

10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.

12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.

14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.

15. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit.
A. Disconnection

WARNING! Collect the air conditioner refrigerant gas (R134a).

If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly,
when collecting or adding it, you must be qualified for handling the refrigerant and put on
protective goggles.

B. Connection

i. When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter
them.

ii. When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints.

iii. Check that each O-ring is not damaged or deteriorated.

00-4 d PC400LC-8
FOREWORD SAFETY
iv. When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.

★ Example of O-ring (Fitted to every joint of hoses and tubes)

★ For tightening torque, see the precautions for installation in each
section of "Disassembly and assembly".

PC400LC-8 00-5 d
FOREWORD GENERAL
12
GENERAL 00

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.

STANDARD VALUE TABLE

This section explains the standard values for new machine and judgement criteria for testing, adjusting and
troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts
in troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.

TROUBLESHOOTING

Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.

DIAGRAMS AND DRAWINGS

This section has the foldout drawings for the machine.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.

00-6 d PC400LC-8
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00

Volumes 00

Revisions 00

Shop manuals are issued as a guide to carrying out repairs.

Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows:
between the title page and SAFETY page.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series Symbols 00

Electrical volume: Each issued as one to cover all models So that the shop manual can be of ample practical use,
Attachment volume: Each issued as one to cover all models important places for safety and quality are marked with the
following symbols.
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment
be available. Special safety precautions are
Safety necessary when performing the
work.
Distribution And Updating 00

Special technical precautions or

Any additions, amendments or other changes will be sent to other precautions for preserving
★ Caution
your distributors. Get the most up-to-date information before standards are necessary when
you start any work. performing the work.
Weight of parts or systems.
Filing Method 00
Caution necessary when
Weight selecting hoisting wire or when
1. See the page number on the bottom of the page. File the working posture is important,
pages in correct order. etc.
2. Following examples show how to read the page number:
Example: Places that require special
Tightening
attention for tightening torque
torque
10 - 3 during assembly.
Places to be coated with
Item number (10. Structure and Function) Coat
adhesives and lubricants etc.
Consecutive page number for each item Places where oil, water or fuel
Fill
must be added, and the capacity.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as Places where oil or water must
in the example. Drain be drained, and quantity to be
Example: drained.
10-4
10-4-1
Added pages
10-4-2

10-5

Revised Edition Mark 00

When a manual is revised, an edition mark (123…) is

recorded on the bottom outside corner of the pages.

PC400LC-8 00-7 d
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00

Hoisting 00
can result. Hooks have maximum strength at the middle
portion.

WARNING! Heavy parts (25 kg or more)

must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the
symbol.

● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the 3. Do not sling a heavy load with one rope alone, but sling
relative parts. with two or more ropes symmetrically wound on to the
2. Check for existence of another part causing interface load.
with the part to be removed.
WARNING! Slinging with one rope may
Wire Ropes 00
cause turning of the load
during hoisting, untwisting of
1. Use adequate ropes depending on the weight of parts to the rope, or slipping of the
be hoisted, referring to the table below: rope from its original winding
position on the load, which
Wire ropes can result in a dangerous
(Standard “Z” or “S” twist ropes without galvanizing) accident
Rope diameter Allowable load 4. Do not sling a heavy load with ropes forming a wide
mm kN tons hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
10 9.8 1.0 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
11.2 13.7 1.4 hoisting is made with two ropes, each of which is
allowed to sling up to 1000 kg vertically, at various
12.5 15.7 1.6 hanging angles. When two ropes sling a load vertically,
up to 2000 kg of total weight can be suspended. This
14 21.6 2.2 weight becomes 1000 kg when two ropes make a 120°
16 27.5 2.8 hanging angle. On the other hand, two ropes are subject
to an excessive force as large as 4000 kg if they sling a
18 35.3 3.6 2000 kg load at a lifting angle of 150°.

20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of
the breaking strength of the rope used.Sling wire ropes
from the middle portion of the hook.
2. Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident

00-8 d PC400LC-8
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00

WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual
pressure from hydraulic tank.

WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected.
Accordingly, prepare an oil receiving
container.

Type 1 00

Disconnection 00

1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not
hold the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.

4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.

Connection 00

1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.

PC400LC-8 00-9 d
Komatsu Hydraulic Excavator Pc400 8 88888 Shop Manual
Full download: http://manualplace.com/download/komatsu-hydraulic-excavator-pc400-8-88888-shop-manual/
FOREWORD PUSH PULL COUPLER

Type 2 00

Disconnection 00

1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a
of the hexagonal portion at the male end.

2. Hold in the condition in Step 1, and turn the lever (4) to the
right - clockwise.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.

Connection 00

1. Hold the connector of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.

00-10 d PC400LC-8
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