Table of Contents
CONTENTS
No. of page
01 GENERAL
SPECIFICATION DRAWINGS 01- 2
SPECIFICATIONS 01- 4
WEIGHT TABLE 01- 8
FUEL, COOLANT AND LUBRICANTS 01- 12
SPECIFICATION DRAWINGS
SPECIFICATIONS
PC400-7, PC400LC-7
: The “Mi” mode is on the multi-monitor specification machine only
PC450-7, PC450LC-7
: The “Mi” mode is on the multi-monitor specification machine only
WEIGHT TABLE
PC400-7, PC400LC-7
k This weight table is for use when handling components or when transporting the machine.
Unit: kg
PC450-7, PC450LC-7
Unit: kg
FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE RELATED PARTS
1. Drive plate
2. Torsion spring
3. Stopper pin
4. Friction plate
5. Damper assembly
6. Muffler
7. Rear engine mount
8. Front engine mount
RADIATOR•OIL COOLER•AFTERCOOLER
1. Oil cooler
2. Radiator
3. Radiator cap
4. Reservoir tank
5. Net
6. Shroud
7. Radiator inlet hose
8. Radiator outlet hose
9. Aftercooler
10. Condenser
11. Fuel cooler
POWER TRAIN
1. Idler
2. Center swivel joint
3. Control valve
4. Final drive
5. Travel motor (KMV 200ADT-2)
6. Engine (SAA6D125-3E)
7. Hydraulic pump (HPV190+190)
8. Travel speed solenoid valve
9. Swing brake solenoid valve
10. Swing machinery
11. Swing motor (KMF230ABE-5)
12. Swing circle
FINAL DRIVE
1. Level plug
2. Drain plug
3. No. 1 planetary gear (No. of teeth: 43)
4. No. 1 sun gear (No. of teeth: 10)
5. No. 2 sun gear (No. of teeth: 18)
6. No. 1 planetary carrier
7. No. 2 planetary carrier
8. Cover
9. Ring gear (No. of teeth: 98)
10. Sprocket
11. Floating seal
12. Travel motor
13. No. 2 planetary gear (No. of teeth: 38)
SWING MACHINERY
1. Swing pinion (No. of teeth: 13)
2. Cover
3. Case
4. No. 2 planetary gear
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
11. No. 1 planetary carrier
12. No. 2 planetary carrier
13. Drain plug
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 84)
2. Ball
3. Swing circle outer race
a. Inner race soft zone “S” position
b. Outer race soft zone “S” position
TRACK FRAME AND RECOIL SPRING
1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Recoil spring
9. Front guard
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
TRACK SHOE
TRIPLE GROUSER SHOE
HYDRAULIC PIPING DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler
7. Hydraulic filter
8. Hydraulic pump
9. L.H. travel motor
10. Hydraulic tank
11. Multi-pattern selector valve
12. L.H. PPC valve
13. Safety lever (electric type)
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment circuit selector valve
18. Holding valve
19. Accumulator
20. Solenoid valve assembly
HYDRAULIC TANK
1. Oil filler cap
2. Breather
3. Hydraulic tank
4. Sight gauge
5. Strainer
6. Filter element
7. Strainer
8. Bypass valve
HYDRAULIC PUMP
1. Front main pump
2. Rear main pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve
7. Variable volume valve
1. Shaft (Front)
2. Cradle
3. Case (Front)
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Shaft (Rear)
11. Case (Rear)
12. Servo piston
1) Operation of pump
i Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When...
ii Center line X of rocker cam (4) maintains swash plate angle in relation to the axial direction...
iii If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) ...
2) Control of discharge amount
1. Plug
2. Locknut
3. Sleeve
4. Spring
5. Seat
6. Spool
7. Piston
8. Sleeve
1. Servo piston assembly
2. Plug
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring
1) When control valve is at neutral position
2) Operation in increase direction for pump discharge amount
3) Operation in decrease direction for pump discharge amount
4) When servo piston is balanced
1) When pump controller is normal
a. When the load on the actuator is small and pump pressures PP1 and PP2 are low
b. When load on actuator is large and pump discharge pressure is high
2) When pump controller is abnormal and emergency pump drive switch is ON
a. When load on main pump is light
b. When main pump load is heavy
LS(pc)-EPC VALVE
1. Body
2. Spool
3. Spring
4. Rod
5. Coil
6. Plunger
7. Connector
1. When signal current is 0 (coil de-energized)
2. When signal current is very small (coil energized)
3. When signal current is maximum (coil energized)
variable volume valve
1. Block
2. Plug
3. Spring
4. Piston
CONTROL VALVE
1. 6-spool valve
2. Cover 1
3. Cover 2
4. Pump merge-divider valve
5. Back pressure valve
6. Boom lock valve
7. Boom, arm Hi valve
8. Quick return valve
9. Boom Hi check valve
1. Unload valve
2. Pressure compensation valve (Arm OUT)
3. Pressure compensation valve (Right travel reverse)
4. Pressure compensation valve (Left swing)
5. Pressure compensation valve (Boom RAISE)
6. Pressure compensation valve (Left travel reverse)
7. Pressure compensation valve (Bucket CURL)
8. Pressure compensation valve (Boom RAISE)
9. Pressure compensation valve (Arm IN)
10. Pressure compensation valve (Bucket DUMP)
11. Pressure compensation valve (Left travel forward)
12. Pressure compensation valve (Boom LOWER)
13. Pressure compensation valve (Right swing)
14. Pressure compensation valve (Right travel forward)
15. Pressure compensation valve (Arm IN)
16. Main relief valve
1. Spool (Arm)
2. Spool (Right travel)
3. Spool (Swing)
4. Spool (Boom)
5. Spool (Left travel)
6. Spool (Bucket)
7. Spool (Boom Hi)
8. Spool (Arm Hi)
9. Unload valve
10. Main relief valve
1. Safety-suction valve (Arm OUT)
2. Suction valve (Right travel reverse)
3. Suction valve (Boom RAISE)
4. Suction valve (Left travel reverse)
5. Safety-suction valve (Boom Hi)
6. Safety-suction valve (Arm IN)
7. Safety-suction valve (Bucket DUMP)
8. Suction valve (Left travel forward)
9. Safety-suction valve (2-stage) (Boom LOWER)
10. Suction valve (Right travel forward)
11. Safety-suction valve (Arm IN)
12. LS shuttle valve (Arm, right travel)
13. LS select valve
14. LS shuttle valve (Boom, left travel, bucket)
15. LS check valve
16. Pressure relief plug
1. Unload valve
2. Main relief valve
3. Safety valve (Boom RAISE)
4. Lift check valve
5. Safety-suction valve
6. Spool
7. Pressure compensation valve (OUT)
8. LS shuttle valve
9. Pressure compensation valve (IN)
10. Safety-suction valve
11. Check valve for regeneration circuit
12. Suction valve
13. Spool
14. Pressure compensation valve (Reverse)
15. LS shuttle valve
16. Pressure compensation valve (Forward)
17. Suction valve
1. Spool
2. Pressure compensation valve (Left)
3. LS select valve
4. Pressure compensation valve (Right)
5. Suction valve
6. Spool
7. Pressure compensation valve (RAISE)
8. Hydraulic drift prevention valve
9. LS shuttle valve
10. Pressure compensation valve (Lower)
11. Safety-suction valve
12. Check valve for regeneration circuit
13. Pump merge-divider valve (Travel junction valve)
14. Return spring
15. Suction valve
16. Spool
17. Pressure compensation valve (Reverse)
18. LS shuttle valve
19. Pressure compensation valve (Forward)
20. Suction valve
1. Safety-suction valve
2. Spool
3. Pressure compensation valve (CURL)
4. LS shuttle valve
5. Pressure compensation valve (DUMP)
6. Safety-suction valve
7. Boom Hi spool
8. Pressure compensation valve (Boom RAISE)
9. Boom Hi check valve
10. Quick-return valve
11. Pressure compensation valve (Arm IN)
12. Arm Hi spool
13. Safety-suction valve
1. Unload valve
2. Main relief valve
3. Pump merge-divider valve (Main)
4. Return spring
5. Pump merge-divider valve (For LS)
6. Return spring
7. Valve (Sequence valve)
8. Spring (Sequence valve)
9. LS bypass plug
10. Screw
11. Poppet
12. Spring (Pressure reducing valve pilot)
13. Spring (Pressure reducing valve main)
14. Valve (Pressure reducing valve)
15. Spring (Safety valve)
16. Ball
MAIN RELIEF VALVE
1. Spring
2. Poppet
1. When pilot pressure P is OFF: Low-pressure setting The set pressure is determined by the insta...
2. When pilot pressure P is ON: High-pressure setting In addition to the installed load of spring...
CLSS
OUTLINE OF CLSS
1) Fine control not influenced by load
2) Control enabling digging even with fine control
3) Ease of compound operation ensured by flow divider function using area of opening of spool dur...
4) Energy saving using variable pump control
1) Control of pump swash plate
2) Pressure compensation
SELF PRESSURE REDUCING VALVE
1. When engine is stopped
2. When in neutral or load pressure P2 is low (When boom is lowered and arm is in IN position and...
3. When load pressure P2 is high
4. When abnormally high pressure is generated
SWING MOTOR
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Reverse prevention valve
13. Center shaft
14. Center spring
15. Safety valve
16. Check valve
17. Shuttle valve
RELIEF VALVE
1. Outline
2. Function
3. Operation
1) When starting swing
2) When stopping swing
1. When swing lock solenoid valve is deactivated
2. When swing lock solenoid valve is excited
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
1. When brake pressure is being generated at port MB
2. After motor stops
CENTER SWIVEL JOINT
1. Cover
2. Body
3. Slipper seal
4. O-ring
5. Shaft
TRAVEL MOTOR
1. Output shaft
2. Motor case
3. Piston
4. Cylinder
5. Valve plate
6. End cover
7. Slow return valve
8. Regulator piston
9. Plate
10. Disc
11. Check valve spring
12. Check valve
13. Counterbalance valve
14. Spool return spring
15. Safety valve
16. Rgegulator valve
17. Spring
18. Brake spring
19. Brake piston
20. Check valve
1) At low speed (motor swash plate angle at maximumu)
2) At high speed (motor swash plate angle at minimum)
PARKING BRAKE
1. When starting to travel
2. When stopping travel
1) Counterbalance valve, check valve
2) Safety valve (2-direction operation, 2-stage set safety valve)
1) When pressure in chamber MB has become high (when rotating clockwise)
2) When stopping travel (low-pressure setting)
3) When pressure in chamber MA has become high (when rotating counterclockwise)
1) When starting travel (high-pressure setting)
TRAVEL JUNCTION VALVE
VALVE CONTROL
1. Travel PPC valve
2. Service PPC valve
3. Service pedal
4. L.H. travel lever
5. R.H. travel lever
6. R.H. PPC valve
7. R.H. work equipment control lever
8. Solenoid valve
9. Accumulator
10. Control valve
11. Hydraulic pump
12. Junction box
13. L.H. work equipment control lever
14. L.H. PPC valve
TRAVEL PPC SHUTTLE VALVE
1. When travel is at neutral
2. When travel is operated
WORK EQUIPMENT • SWING PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Disc
6. Nut (For connection of lever)
7. Joint
8. Plate
9. Retainer
10. Body
11. Filter
1) At neutral
2) During fine control (neutral o fine control)
3) During fine control (when control lever is returned)
4) At full stroke
TRAVEL PPC VALVE
1. Plate
2. Body
3. Piston
4. Collar
5. Metering spring
6. Centering spring
7. Valve
8. Damper
9. Steering signal
10. Steering signal valve spring
1. While in NEUTRAL
2. While travelling straight
3. When steered or pivot-turned
4. When pivot-turned
SERVICE PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
SOLENOID VALVE
1. PPC lock solenoid valve
2. Travel junction solenoid valve
3. Merge-divider solenoid valve
4. Travel speed solenoid valve
5. Swing brake solenoid valve
6. Machine push-up solenoid valve
8. 2-stage relief solenoid valve
1. Connector
2. Moving core
3. Coil
4. Spool
5. Block
6. Spring
PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
return oil filter
For Breaker
1. Drain plug
2. Element
3. Case
4. Head cover
5. Relief valve
BOOM HYDRAULIC DRIFT PREVENTION VALVE
1. Boom RAISE
2. Boom at HOLD
3. Boom LOWER
ARM HYDRAULIC DRIFT PREVENTION VALVE
(If equipped)
1. Arm DUMP
2. Arm at HOLD
3. Arm IN
4. When abnormally high pressure is generated
quick return valve
1. Arm at OUT
2. Arm at HOLD
LIFT CHECK VALVE
1. While engine is stopped
2. While engine is running
attachment circuit selector valve
1. Spool
2. Spring
1. When attachment other than breaker is installed
2. When breaker is installed
HOLDING VALVE
1. Pilot spool
2. Spring (1st stage of spool)
3. Spring (2nd stage of spool)
4. Safety valve
5. Check valve
6. Spring
1. When the work equipment is in neutral
2. When oil is sent from main valve to cylinder
3. When oil is returned from work equipment cylinder to main valve
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
WORK EQUIPMENT
1. Dimension of arm
2. Dimension of bucket
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Hot water pickup piping
2. Receiver tank
3. Hot water return piping
4. Condenser
5. Air conditioner compressor
6. Refrigerant piping
7. Air conditioner unit
8. Duct
A. Fresh air
B. Recirculated air
C. Hot air/cold air
ENGINE CONTROL
1. Operation of system
2. Components of system
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
3. Engine controller
ELECTRONIC CONTROL SYSTEM
CONTROL FUNCTIONS
TOTAL SYSTEM DIAGRAM
1. Engine and Pump control function
1) Control method in each mode Mode A, Mode E
2) Function to control pump during travel
3) Function to control when emergency pump drive switch is turned ON
2. Pump/Valve control function
1) LS control function
2) Cut-off function
1) 2-stage relief function
3. One-touch power maximizing/machine push-up function
1) One-touch power maximizing function
2) Machine push-up function
4. Auto-deceleration function
5. Auto-warm-up/Overheat prevention function
1) Auto-warm-up function
2) Overheat prevention function
6. Swing control function
1) Swing lock and swing holding brake functions
2) Quick hydraulic oil warm-up function when swing lock switch is turned on
7. Travel control function
1) Pump control function during travel
1. Travel speed change function
i) Manual change with travel speed switch
ii) Automatic change according to engine speed
iii) Automatic changes according to pump discharge pressure
8. ATT flow control, circuit selector function (if equipment)
1) It throttles the ATT PPC pressure and controls the flow when the pedal is depressed fully.
2) In mode B and the other modes, it switches to ATT single acting (B) or double acting (other mo...
9. System component parts
1) Engine revolution sensor
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
2) PPC oil pressure switch
1. Plug
2. Switch
3. Connector
3) Pump pressure sensor
1. Sensor
2. Connector
Pump controller
Input and output signals
MONITOR SYSTEM
1. Monitor section to output alarms when the machine has troubles
2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperat...
1. Monitor panel
1. Wiper motor
2. Preheating monitor
3. Swing lock monitor
4. Engine water temperature monitor
5. Hydraulic oil temperature gauge
6. Engine water temperature gauge
7. Working mode monitor
8. Service monitor
9. Travel speed monitor
10. Fuel gauge
11. Fuel level monitor
12. Hydraulic oil temperature monitor
13. Power max. monitor
14. Auto-deceleration monitor
15. Radiator water level caution
16. Battery charge caution
17. Engine oil pressure caution
18. Engine oil level caution
19. Air cleaner clogging
20. Maintenance time warning caution
1. Selector switch
2. Selector switch
3. Display brightness, contrast adjustment switch
4. Control switch
5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch
1. A mode, E mode
1) Press select switch (1) on the monitor to move to the adjustment screen.
2) Press control switch (2) to select the flow level.
3) After completing the level selection, press input confirmation switch (3).
2. B mode
1) Press select switch (1) on the monitor to move to the screen for selecting the 3-stage flow le...
2) Press control switch (2), or input [01] – [03] with the numeral 10-key pad to choose one on th...
3) After completing the level selection, press input confirmation switch (3).
4) After the flow level is confirmed, the screen changes to the screen shown in the diagram on th...
5) Press control switch (2) and select the flow level.
6) After completing the level selection, press input confirmation switch (3).
7) Check the set value with the working mode monitor.
MAINTENANCE FUNCTION
Method of checking status maintenance items
1. Press maintenance switch (1) and switch to the maintenance list display screen.
2. Press control switch (2), or use the 10-key pad to input the number (01 – 10) of the maintenan...
maintenance operation
1. After completing the selection, press input confirmation switch (3).
2. Use the maintenance reset screen to check the content, and if there is any problem, press inpu...
3. Check the content on the check screen, and if there is no problem, press input confirmation sw...
brightness, contrast adjustment function
Adjustment method
1. Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen.
2. Press control switch (2), or use the 10-key pad to input the number (00 – 02) to select either...
3. Press control switch (2) and adjust the brightness and contrast as desired.
service meter check function
display lcd check function
user code display function
SENSOR
1. Connector
2. Bracket
3. Float
4. Switch
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
1. Thermistor
2. Body
3. Tube
4. Tube
5. Wire
6. Connector
1. Float
2. Connector
3. Cover
4. Variable resistor
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM (1/2) 90- 3
HYDRAULIC CIRCUIT DIAGRAM (2/2) 90- 5
ELECTRICAL CIRCUIT DIAGRAM (1/5) 90- 7
ELECTRICAL CIRCUIT DIAGRAM (2/5) 90- 9
ELECTRICAL CIRCUIT DIAGRAM (3/5) 90- 11
ELECTRICAL CIRCUIT DIAGRAM (4/5) 90- 13
ELECTRICAL CIRCUIT DIAGRAM (5/5) 90- 15
AIR CONDITIONER ELECTRICAL CIRCUIT 90- 17
